GP Series Service Manual PDF

®
Diagnostic
Repair
Manual
GP Series Portable Generators
MODELS:
GP1800
GP3250
GP5000
GP5500
GP6500
GP7000
GP8000
Portable generators
SAFETY
Throughout this publication, “DANGER!” and “CAUTION!” blocks are used to alert the mechanic to special
instructions concerning a particular service or operation that might be hazardous if performed incorrectly or
carelessly. PAY CLOSE ATTENTION TO THEM.
DANGER! UNDER THIS HEADING WILL BE FOUND SPECIAL INSTRUCTIONS WHICH, IF NOT COMPLIED
* WITH, COULD RESULT IN PERSONAL INJURY OR DEATH.

CAUTION! Under this heading will be found special instructions which, if not complied with, could result
* in damage to equipment and/or property.
These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance with these special
instructions plus “common sense” are major accident prevention measures.
NOTICE TO USERS OF THIS MANUAL

This SERVICE MANUAL has been written and published by Generac to aid our dealers' mechanics and com-
pany service personnel when servicing the products described herein.
It is assumed that these personnel are familiar with the servicing procedures for these products, or like or
similar products manufactured and marketed by Generac. That they have been trained in the recommended
servicing procedures for these products, including the use of common hand tools and any special Generac
tools or tools from other suppliers.
Generac could not possibly know of and advise the service trade of all conceivable procedures by which a
service might be performed and of the possible hazards and/or results of each method. We have not under-
taken any such wide evaluation. Therefore, anyone who uses a procedure or tool not recommended by
Generac must first satisfy themselves that neither his nor the products safety will be endangered by the ser-
vice procedure selected.
All information, illustrations and specifications in this manual are based on the latest product information
available at the time of publication.
When working on these products, remember that the electrical system and engine ignition system are capa-
ble of violent and damaging short circuits or severe electrical shocks. If you intend to perform work where
electrical terminals could be grounded or touched, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings of the engine are exposed during service, they should be covered to
prevent accidental entry of foreign material. Entry of such materials will result in extensive damage when the
engine Is started.
During any maintenance procedure, replacement fasteners must have the same measurements and
strength as the fasteners that were removed. Metric bolts and nuts have numbers that indicate their strength.
Customary bolts use radial lines to indicate strength while most customary nuts do not have strength mark-
ings. Mismatched or incorrect fasteners can cause damage, malfunction and possible injury.
REPLACEMENT PARTS
Components on Generac recreational vehicle generators are designed and manufactured to comply with
Recreational Vehicle Industry Association (RVIA) Rules and Regulations to minimize the risk of fire or explo-
sion. The use of replacement parts that are not in compliance with such Rules and Regulations could result
in a fire or explosion hazard. When servicing this equipment, it is extremely important that all components be
properly installed and tightened. If improperly installed and tightened, sparks could ignite fuel vapors from fuel
system leaks.
Specifications........................................................... 2 Test 4 – Field Flash Alternator
(Configuration “A” Only)........................27
Part 1 – General Information................................... 9
Test 5 – Check Brushed Rotor Circuit...............28
Section 1.1 – Generator Fundamentals................. 10
Test 6 – Check Capacitor..................................29
Magnetism........................................................10
Test 7 – Test Brushless DPE Winding...............30
Electromagnetic Fields.....................................10
Test 8 – Test Brushless Stator Windings...........30
Electromagnetic Induction................................10
Test 9 – Test Brushed Stator Windings.............31
A Simple AC Generator....................................11
Test 10 – Check Load Voltage & Frequency.....31
A More Sophisticated AC Generator.................11
Test 11 – Check Load Watts & Amperage........31
Section 1.2 – Measuring Electricity........................ 13
Test 12 – Adjust Voltage Regulator...................31
Meters. .............................................................13
Part 3 – Engine Troubleshooting........................... 33
The VOM...........................................................13
Section 3.1 – 389/206/163cc Troubleshooting
Measuring AC Voltage......................................13 Flowcharts........................................ 34
Measuring DC Voltage......................................13
Section 3.2 – 410cc Troubleshooting Flowcharts... 37
Measuring AC Frequency.................................13
Section 3.3 – Diagnostic Tests............................... 42
Measuring Current............................................14
Test 20 – Check 1.5 Amp Fuse.........................42
Measuring Resistance......................................14
Test 21 – Check Battery & Cables....................42
Electrical Units..................................................15
Test 22 – Check Voltage at
Ohm's Law........................................................15 Starter Contactor (SC).........................42
Section 1.3 – Brushless, Capacitor Test 23 – Check Start-Run-Stop Switch...........42
Excitation System............................. 16
Test 24 – Test OFF-ON Switch..........................43
Introduction.......................................................16
Test 25 – Check Starter Motor..........................43
Stator Assembly................................................16
Test 25 – Check Ignition Spark.........................45
Rotor Assembly.................................................16
Test 26 – Check Spark Plugs............................46
Circuit Breakers................................................16
Test 29 – Check Carburetion............................46
Operation..........................................................17
Test 30 – Choke Test.........................................47
Section 1.4 – Brushed Excitation System.............. 18 Test 33 – Check Valve Adjustment....................47
Introduction.......................................................18 Test 36 – Check Engine / Cylinder Leak Down
Stator Assembly................................................18 Test / Compression Test.......................48
Brush Holder and Brushes................................18 Test 38 – Check Flywheel.................................48
Rotor Residual Magnetism...............................18 Test 39 – Remove Wire 18 / Shutdown Lead....49
Voltage Regulator.............................................18 Test 40 – Check / Adjust Governor
Operation..........................................................18 (389cc Engine).....................................49
Section 1.5 – Testing, Cleaning and Drying........... 20 Test 41 – Check / Adjust Governor
(410cc Engine).....................................50
Insulation Resistance........................................20
Test 45 – Check Oil Level Switch......................51
The Megohmmeter...........................................20
Test 46 – Check Oil Pressure Switch................51
Stator Insulation Resistance Test......................20
Test 49 – Test Recoil Function..........................52
Cleaning the Generator.....................................21
Test 50 – Test Engine Function.........................52
Drying the Generator........................................21
Part 4 – Disassembly.............................................. 53
Part 2 – AC Generators.......................................... 21
Section 4.1 – Major Disassembly........................... 54
Section 2.1 – Brushless Capacitor
Troubleshooting Flowcharts.............. 22 Part 5 – Electrical Data........................................... 71
Section 2.2 – Brushed Excitation Electrical Schematic, GP1850............................... 72
Troubleshooting Flowcharts.............. 24 Electrical Schematic, GP3250............................... 73
Section 2.3 – AC Diagnostic Tests......................... 26 Electrical Schematic, GP5000/5500/GP6500........ 74
Introduction.......................................................26 Wiring Diagram, GP5000/5500/GP6500................ 75
Test 1 – Check No-Load Voltage Electrical Schematic, GP7000E/GP8000E............ 76
and Frequency.....................................26
Wiring Diagram, GP7000E/GP8000E.................... 77
Test 2 – Check Circuit Breaker.........................26
Electrical Formulas................................................ 78
Test 3 – Check Continuity of
Receptacle Panel.................................26
Page 1
Specifications – GP1800
Product Series GP1800

A/C Rated Output Watts: 1800
A/C Maximum Output Watts: 2050
A/C Voltage 120VAC
A/C Frequency 60 Hz
Rated 120 VAC Amperage 7.5
Max 120 VAC Amperage 8.5
Engine Displacement 163cc
Engine Type OHV
Engine RPM 3600
Recommended Oil 5W30
Lubrication Method Splash Sump
Choke Type Manual Lever
M
Fuel Shut Off Manual Lever
Idle Control Full Speed
Starting Method Manual
Battery n/a
Battery Size n/a
Low Oil Shutdown Method Low Level
Start Switch Type On/Off Toggle
H A Switch Location Control Panel
Single-Point Lifting Eye N/A
Outlets Fuel Gauge Built-In
A (2) 5-20R 120V Fuel Tank Capacity (Gal) 4

Fuel Tank Capacity (Liters) 15.14
Circuit Breakers Run Time at 50% (Hours) 14
M (1) 20A Cord Set No
Handle Style Folding
Other Features
Wheel type n/a
H On/Off Switch
Length (L) 23.5
Width (W) 17
Height (H) 17.5
Extended Length (EL) 23.5
Unit Weight (lbs) 79
Spark Plug Type NGK BPR4ES
or Champion
RN14YC
Spark Plug Gap 0.028"-0.031"
(0.7-0.8mm)
Oil Capacity 0.634 quart
(0.6 liter)
Page 2

A/C Voltage 120VAC
A/C Frequency 60 Hz
Rated 120 VAC Amperage 13.5
Max 120 VAC Amperage 15.6
Engine Type OHV
Engine RPM 3600
Choke Type Manual Lever M
Battery n/a
Battery Size n/a
Start Switch Type On/Off Toggle
H A
Switch Location Control Panel
Outlets
Fuel Gauge Built-In
A (4) 5-20R 120V
Fuel Tank Capacity (Gal) 4
Fuel Tank Capacity (Liters) 15.14 Circuit Breakers
Run Time at 50% (Hours) 13.5 M (2) 20A
Cord Set No
Handle Style Folding Other Features
Wheel type 7.0" Solid Wheels H On/Off Switch
Length (L) 25.5
Width (W) 21
Height (H) 19
Extended Length (EL) 39.5
Spark Plug Type NGK BPR4ES
or Champion
RN14YC
(0.7-0.8mm)
(0.6 liter)
Page 3

A/C Voltage 120/240VAC
A/C Frequency 60 Hz
Rated 120/240 VAC Amperage 20.8
Max 120/240 VAC Amperage 26.0
Engine Type OHV
Engine RPM 3600
A H
B Fuel Shut Off Manual Lever
Battery n/a
Battery Size n/a
Start Switch Type 3-Position
Switch Location On Engine
N M Fuel Gauge Built-In
Fuel Tank Capacity (Gal) 6.6
Receptacles
A (4) 5-20R 120V
Run Time at 50% (Hours) 10
B L14-30R Twist-Lock 120/240V
Cord Set No
Handle Style Folding Interlocked
Circuit Breakers
Wheel type 9.5" Solid Wheels
M (2) 20A
N (2) 25A Length (L) 33.5
Width (W) 26.5
Other Features Height (H) 27.5
Hour Meter with Extended Length (EL) 47
H
Maintenance Reset
Spark Plug Type NHSP F7RTC or
Champion RN9YC
(0.7-0.8mm)
(1.1 liter)
Page 4

A/C Frequency 60 Hz
Engine Type OHV
Engine RPM 3600
A H
Fuel Shut Off Manual Lever B
Battery n/a
Battery Size n/a
Fuel Gauge Built-In N M
Fuel Tank Capacity (Gal) 6.6
Receptacles
A (4) 5-20R 120V
Run Time at 50% (Hours) 10
B L14-30R Twist-Lock 120/240V
Cord Set No
Circuit Breakers
M (2) 20A
Length (L) 33.5 N (2) 25A
Width (W) 26.5
Height (H) 27.5 Other Features
Extended Length (EL) 47 Hour Meter with

H
Maintenance Reset
Champion RN9YC
(0.7-0.8mm)
(1.1 liter)
Page 5

A/C Frequency 60 Hz
Engine Type OHV
Engine RPM 3600
A Choke Type Manual Lever
B H
Battery n/a
Battery Size n/a
N M
Fuel Gauge Built-In
Outlets Fuel Tank Capacity (Gal) 6.6
A (4) 5-20R 120V Fuel Tank Capacity (Liters) 24.98
B L14-30R Twist-Lock 120/240V Run Time at 50% (Hours) 9
Cord Set No
Circuit Breakers
M (2) 20A
N (2) 30A
Length (L) 33.5
Other Features Width (W) 26.5
H Hour Meter with Maintenance Reset Height (H) 27.5

Extended Length (EL) 47
Champion RN9YC
(0.7-0.8mm)
(1.1 liter)
Page 6
Specifications – GP7000/GP7000E

A/C Frequency 60 Hz
Engine Type OHVI
Engine RPM 3600
Lubrication Method Full Pressure
Fuel Shut Off Manual Lever A
B H
Starting Method GP7000 Manual
Starting Method GP7000E Manual or Electric
Battery Size (if equipped) 12VDC 10 Ahr
Low Oil Shutdown Method Low Pressure
Fuel Gauge Built-In N M
Fuel Tank Capacity (Liters) 30.28 Outlets
Run Time at 50% (Hours) 11 A (4) 5-20R 120V
Cord Set No B L14-30R Twist-Lock 120/240V
Circuit Breakers
Spark Plug Type Champion RC14YC M (2) 20A
Spark Plug Gap 0.030" (0.76mm) N (2) 30A
Oil Capacity 1.5 quart w/filter

Other Features
H Hour Meter with Maintenance Reset
Page 7
Specifications – GP8000/GP8000E
Product Series GP8000/GP8000E

A/C Frequency 60 Hz
Engine Type OHVI
Engine RPM 3600
Lubrication Method Full Pressure
A Fuel Shut Off Manual Lever

B H
Starting Method GP8000 Manual
Starting Method GP8000E Manual or Electric
Battery Size (if equipped) 12VDC 10 Ahr
Low Oil Shutdown Method Low Pressure
N M Fuel Gauge Built-In
Outlets Fuel Tank Capacity (Liters) 30.28
A (4) 5-20R 120V Run Time at 50% (Hours) 8
B L14-30R Twist-Lock 120/240V Cord Set No
Circuit Breakers
M (2) 20A Spark Plug Type Champion RC14YC
N (2) 30A Spark Plug Gap 0.030" (0.76mm)
Oil Capacity 1.5 quart w/filter
Other Features
H Hour Meter with Maintenance Reset
Page 8
Table of contents
Part Title Page
1.1 Generator Fundamentals 10
PART 1 1.2
1.3
Measuring Electricity
Brushless, Capacitor Excitation
13
16
GENERAL
System
1.4 Brushed Excitation System 18
INFORMATION 1.5 Testing, Cleaning and Drying 20
Part 1 – General Information................................... 9 Section 1.3 – Brushless, Capacitor

Excitation System............................. 16
Section 1.1 – Generator Fundamentals................. 10
Introduction.......................................................16
Magnetism........................................................10
Stator Assembly................................................16
Electromagnetic Fields.....................................10
Rotor Assembly.................................................16
Electromagnetic Induction................................10
Circuit Breakers................................................16
A Simple AC Generator....................................11
Operation..........................................................17
A More Sophisticated AC Generator.................11
Section 1.4 – Brushed Excitation System.............. 18
Section 1.2 – Measuring Electricity........................ 13
Introduction.......................................................18
Meters. .............................................................13
Stator Assembly................................................18
The VOM...........................................................13
Brush Holder and Brushes................................18
Measuring AC Voltage......................................13
Rotor Residual Magnetism...............................18
Measuring DC Voltage......................................13
Voltage Regulator.............................................18
Measuring AC Frequency.................................13
Operation..........................................................18
Measuring Current............................................14
Measuring Resistance......................................14 Section 1.5 – Testing, Cleaning and Drying........... 20
Electrical Units..................................................15 Insulation Resistance........................................20
Ohm's Law........................................................15 The Megohmmeter...........................................20
Stator Insulation Resistance Test......................20
Cleaning the Generator.....................................21
Drying the Generator........................................21
Page 9
Section 1.1
Part 1 General information
Generator Fundamentals
Magnetism NOTE: The “right hand rule” is based on the “cur-

rent flow” theory which assumes that current
Magnetism can be used to produce electricity and flows from positive to negative. This is opposite
electricity can be used to produce magnetism. the “electron” theory, which states that current
Much about magnetism cannot be explained by our flows from negative to positive.
present knowledge. However, there are certain pat-
terns of behavior that are known. Application of these
behavior patterns has led to the development of gen-
erators, motors and numerous other devices that uti-
lize magnetism to produce and use electrical energy.
See Figure 1. The space surrounding a magnet is per-
meated by magnetic lines of force called “flux”. These
lines of force are concentrated at the magnet's north
and south poles. They are directed away from the
magnet at its north pole, travel in a loop and re-enter
the magnet at its south pole. The lines of force form
definite patterns which vary in intensity depending on
the strength of the magnet. The lines of force never
cross one another. The area surrounding a magnet in
which its lines of force are effective is called a “mag-
netic field”.
Like poles of a magnet repel each other, while unlike
poles attract each other.
Figure 2. The Right Hand Rule
Electromagnetic Induction
An electromotive force (EMF) or voltage can be pro-
duced in a conductor by moving the conductor so that
it cuts across the lines of force of a magnetic field.
Similarly, if the magnetic lines of force are moved so
that they cut across a conductor, an EMF (voltage)
will be produced in the conductor. This is the basic
principal of the revolving field generator.
Figure 3, below, illustrates a simple revolving field
generator. The permanent magnet (Rotor) is rotated
so that its lines of magnetic force cut across a coil of
wires called a Stator. A voltage is then induced into
Figure 1. Magnetic Lines of Force the Stator windings. If the Stator circuit is completed
by connecting a load (such as a light bulb), current
will flow in the circuit and the bulb will light.
Electromagnetic Fields
All conductors through which an electric current is
flowing have a magnetic field surrounding them. This
field is always at right angles to the conductor. If a
compass is placed near the conductor, the compass
needle will move to a right angle with the conductor.
The following rules apply:
• The greater the current flow through the conductor,
the stronger the magnetic field around the conductor.
• The increase in the number of lines of force is
directly proportional to the increase in current flow
and the field is distributed along the full length of
the conductor.
• The direction of the lines of force around a conduc-
tor can be determined by what is called the “right
hand rule”. To apply this rule, place your right hand
around the conductor with the thumb pointing in
the direction of current flow. The fingers will then be Figure 3. A Simple Revolving Field Generator
pointing in the direction of the lines of force.
Page 10
General information Part 1
Section 1.1
A Simple AC Generator A More Sophisticated AC Generator

Figure 4 shows a very simple AC Generator. The gen- Figure 6 and 7 show two methods of creating alternat-
erator consists of a rotating magnetic field called a ing current that are implemented on GP Series por-
ROTOR and a stationary coil of wire called a STATOR. table generator product.
The ROTOR is a permanent magnet which consists of Figure 6 shows a consistent voltage being induced to
a SOUTH magnetic pole and a NORTH magnetic pole. the rotor from a capacitor which is installed in series
As the MOTOR turns, its magnetic field cuts across with the DPE winding. As a result a regulated voltage
the stationary STATOR. A voltage is induced Into is induced into the STATOR.
the STATOR windings. When the magnet's NORTH
pole passes the STATOR, current flows in one direc-
tion. Current flows in the opposite direction when the
magnet's SOUTH pole passes the STATOR. This con-
stant reversal of current flow results in an alternating
AC OUTPUT
current (AC) waveform that can be diagrammed as 120 VAC STATOR STATOR
shown in Figure 5. 240 VAC
The ROTOR may be a 2-pole type having a single 120 VAC

NORTH and a single SOUTH magnetic pole. Some ROTOR
ROTORS are 4-pole type with two SOUTH and two
NORTH magnetic poles. The following apply:
1. The 2-pole ROTOR must be turned at 3600 rpm to pro-
duce an AC frequency of 60 Hertz, or at 3000 rpm to GENERATOR
deliver an AC frequency of 50 Hertz.
2. The 4-pole ROTOR must operate at 1800 rpm to deliver + -
a 60 Hertz AC frequency or at 1500 rpm to deliver a 50 CAPACITOR
Hertz AC frequency.
Figure 6. Capacitive Discharge

Figure 7 shows a regulated direct current being deliv-
ered into the ROTOR windings via carbon BRUSHES
AND SLIP RINGS. This results in the creation of
STATOR a regulated magnetic field around the ROTOR. As
a result, a regulated voltage is induced into the
STATOR. Regulated current delivered to the ROTOR
is called “EXCITATION” current.
ROTOR
AC OUTPUT
120 V
MAGNETIC FIELD STATOR STATOR
240 V
120 V
Figure 4. A Simple AC Generator
-
+
DC CURRENT
CURRENT VOLTAGE
(+)
BRUSHES
0 180 360 SLIP
RINGS
(-)
ONE CYCLE Figure 7. Direct Excitation
Figure 5. Alternating Current Sine Wave

Page 11
Section 1.1
TO LOAD TO LOAD
MLB = MAIN LINE MLB = MAIN LINE
CIRCUIT BREAKER
MLB CIRCUIT BREAKER
MLB
240 VAC 240 VAC

120 VAC 120 VAC 120 VAC 120 VAC SENSING
STATOR STATOR STATOR STATOR

POWER POWER POWER POWER
WINDING WINDING WINDING WINDING
MAGNETIC MAGNETIC
FIELD FIELD
ENGINE - ENGINE -
DIRECT ROTOR DIRECT ROTOR - +
DRIVE DRIVE
MAGNETIC MAGNETIC
FIELD FIELD
STATOR STATOR AUTOMATIC

EXCITATION EXCITATION VOLTAGE
WINDING WINDING REGULATOR
CAPACITOR
A CAPACITIVE DISCHARGE B DIRECT EXCITATION
Figure 8. Generator Operating Diagram
The revolving magnetic field is driven by the engine 2. See Figure 8.

at constant speed. This constant speed is maintained
by a mechanical engine governor. Units with a 2-pole A. During startup, the “residual” voltage that
rotor require an operation speed of 3600 rpm to deliv- is induced into the DPE winding will initially
er a 60 Hertz AC output. charge the capacitor to a greater potential.
When the capacitor is discharged the voltage
Generator operation may be described briefly as follows. is in turn induced back into the Rotor which will
1. Some “residual” magnetism is normally present in the exponentially raise the voltage to 120/240.
Rotor, which is sufficient to induce approximately 1 to 2 B. During startup, the “residual” voltage that is
Volts AC in to the Stator’s AC Power Windings and DPE induced into the DPE winding will turn on the
winding. voltage regulator allowing DC excitation current
to be delivered to the rotor and raise the voltage
to 120/240.
Page 12
Section 1.2
Meters Measuring AC Voltage

Devices used to measure electrical properties are called An accurate AC voltmeter or a VOM may be used to
meters. Meters are available that allow one to measure read the generator's AC output voltage. The following
(a) AC voltage, (b) DC voltage, (c) AC frequency, and apply:
(d) resistance in ohms. The following apply: 1. Always read the generator's AC output voltage only at
• To measure AC voltage, use an AC voltmeter. the unit's rated operating speed and AC frequency.
• To measure DC voltage, use a DC voltmeter.
• Use a frequency meter to measure AC frequency in 2. The generator's Voltage Regulator can be adjusted for
“Hertz” or “cycles per second”. correct output voltage only while the unit is operating at
• Use an ohmmeter to read circuit resistance, in its correct rated speed and frequency.
“Ohms”.
3. Only an AC voltmeter may be used to measure AC
voltage. DO NOT USE A DC VOLTMETER FOR THIS
The VOM PURPOSE.
A meter that will permit both voltage and resistance to DANGER! GENERATORS PRODUCE HIGH
be read is the “volt-ohm-milliammeter” or “VOM”.
Some VOMs are of the “analog” type (not shown).
These meters display the value being measured by
* AND DANGEROUS VOLTAGES. CONTACT
WITH HIGH VOLTAGE TERMINALS WILL
physically deflecting a needle across a graduated RESULT IN DANGEROUS AND POSSIBLY
scale. The scale used must be interpreted by the user. LETHAL ELECTRICAL SHOCK.
“Digital” VOMs (Figure 1) are also available and are
generally very accurate. Digital meters display the
measured values directly by converting the values to Measuring DC Voltage
numbers.
NOTE: Standard AC voltmeters react to the A DC voltmeter or a VOM may be used to measure
AVERAGE value of alternating current. When work- DC voltages. Always observe the following rules:
ing with AC, the effective value is used. For that 1. Always observe correct DC polarity.
reason a different scale is used on an AC voltme-
ter. The scale is marked with the effective or “rms” a. Some VOM's may be equipped with a polar-
value even though the meter actually reacts to the ity switch.
average value. That is why the AC voltmeter will b. On meters that do not have a polarity switch,
give an incorrect reading if used to measure direct DC polarity must be reversed by reversing
current (DC). the test leads.
2. Before reading a DC voltage, always set the meter to a
higher voltage scale than the anticipated reading. If in
doubt, start at the highest scale and adjust the scale
downward until correct readings are obtained.
3. The design of some meters is based on the “current
flow” theory while others are based on the “electron flow”
theory.
a. The “current flow” theory assumes that direct
current flows from the positive (+) to the
negative (-).
b. The “electron flow” theory assumes that cur-
rent flows from negative (-) to positive (+).
NOTE: When testing generators, the “current flow”
theory is applied. That is, current is assumed to
flow from positive (+) to negative (-).
Measuring AC Frequency
The generator's AC output frequency is proportional to
Figure 1. Digital VOM Rotor speed. Generators equipped with a 2-pole Rotor
must operate at 3600 rpm to supply a frequency of 60
Hertz. Units with 4-pole Rotor must run at 1800 rpm to
deliver 60 Hertz.
Page 13
Section 1.2
Correct engine and Rotor speed is maintained by an NOTE: If the physical size of the conductor or amme-
engine speed governor. For models rated 60 Hertz, ter capacity does not permit all lines to be measured
the governor is generally set to maintain a no-load fre- simultaneously, measure current flow in each indi-
quency of about 62 Hertz with a corresponding output vidual line. Then, add the individual readings.
voltage of about 124 volts AC line-to-neutral. Engine
speed and frequency at no-load are set slightly high In-Line:
to prevent excessive rpm and frequency droop under Alternatively, to read the current flow in AMPERES, an
heavy electrical loading. in-line ammeter may be used. Most Digital Volt Ohm
Meters (VOM) will have the capability to measure
amperes.
Measuring Current
This usually requires the positive meter test lead to be
connected to the correct amperes plug, and the meter
Clamp-on: to be set to the amperes position. Once the meter is
To read the current flow, in AMPERES, a clamp-on properly set up to measure amperes the circuit being
ammeter may be used. This type of meter indicates measured must be physically broken. The meter will
current flow through a conductor by measuring the be in-line or in series with the component being mea-
strength of the magnetic field around that conductor. sured.
The meter consists essentially of a current transform- In Figure 4 the control wire to a relay has been
er with a split core and a rectifier type instrument con- removed. The meter is used to connect and supply
nected to the secondary. The primary of the current voltage to the relay to energize it and measure the
transformer is the conductor through which the current amperes going to it.
to be measured flows. The split core allows the instru-
ment to be clamped around the conductor without
disconnecting it.
Current flowing through a conductor may be measured
safely and easily. A line-splitter can be used to measure
current in a cord without separating the conductors. 1.00 A
BATTERY
- + RELAY
Figure 4. A VOM as an In-line meter
Measuring Resistance
The volt-ohm-milliammeter may be used to measure
Figure 2. Clamp-On Ammeter the resistance in a circuit. Resistance values can be
very valuable when testing coils or windings, such as
the Stator and Rotor windings.
When testing Stator windings, keep in mind that the
resistance of these windings is very low. Some meters
are not capable of reading such a low resistance and
will simply read CONTINUITY.
If proper procedures are used, the following conditions
can be detected using a VOM:
• A “short-to-ground” condition in any Stator or Rotor
winding.
• Shorting together of any two parallel Stator windings.
• Shorting together of any two isolated Stator windings.
• An open condition in any Stator or Rotor winding.
Figure 3. A Line-Splitter
Page 14
Section 1.2
Component testing may require a specific resis- OHM:

tance value or a test for INFINITY or CONTINUITY. The OHM is the unit of RESISTANCE. In every circuit
Infinity is an OPEN condition between two electrical there is a natural resistance or opposition to the flow
points, which would read as no resistance on a VOM. of electrons. When an EMF is applied to a complete
Continuity is a CLOSED condition between two electri- circuit, the electrons are forced to flow in a single
cal points, which would be indicated as very low resis- direction rather than their free or orbiting pattern. The
tance or “ZERO” on a VOM. resistance of a conductor depends on (a) its physical
makeup, (b) its cross-sectional area, (c) its length, and
(d) its temperature. As the conductor's temperature
Electrical Units increases, its resistance increases in direct proportion.
One (1) ohm of resistance will permit one (1) ampere
AMPERE: of current to flow when one (1) volt of electromotive
force (EMF) is applied.
The rate of electron flow in a circuit is represented
by the AMPERE. The ampere is the number of elec-
trons flowing past a given point at a given time. One Ohm's Law
AMPERE is equal to just slightly more than six thou-
sand million billion electrons per second (6.25 x 1018). A definite and exact relationship exists between VOLTS,
With alternating current (AC), the electrons flow first in OHMS and AMPERES. The value of one can be calcu-
one direction, then reverse and move in the opposite lated when the value of the other two are known. Ohm's
direction. They will repeat this cycle at regular inter- Law states that in any circuit the current will increase
vals. A wave diagram, called a “sine wave” shows that when voltage increases but resistance remains the
current goes from zero to maximum positive value, same, and current will decrease when resistance
then reverses and goes from zero to maximum nega- Increases and voltage remains the same.
tive value. Two reversals of current flow is called a
cycle. The number of cycles per second is called fre-
quency and is usually stated in “Hertz”.
VOLT:
VOLTS
The VOLT is the unit used to measure electrical
PRESSURE, or the difference in electrical potential (E)
that causes electrons to flow. Very few electrons will
flow when voltage is weak. More electrons will flow as
voltage becomes stronger. VOLTAGE may be consid- AMPS OHMS
ered to be a state of unbalance and current flow as (I) (R)
an attempt to regain balance. One volt is the amount
of EMF that will cause a current of 1 ampere to flow
through 1 ohm of resistance.
Conductor of a
Circuit
Figure 6. Ohm's Law
OHM - Unit measuring resistance
-
If AMPERES is unknown while VOLTS and OHMS are
+
or opposition to flow
known, use the following formula:
AMPERES = VOLTS
OHMS
AMPERE - Unit measuring rate of If VOLTS is unknown while AMPERES and OHMS are
current flow (number of electrons known, use the following formula:
past a given point)
VOLTS = AMPERES x OHMS

VOLT - Unit measuring force or
difference in potential
causing current flow If OHMS is unknown but VOLTS and AMPERES are
known, use the following:
= VOLTS
Figure 5. Electrical Units OHMS AMPERES
Page 15
Section 1.3 Part 1 General information
BRUSHLESS, CAPACITOR EXCITATION SYSTEM
Introduction a tapered crankshaft and is held in place with a single

through bolt.
A typical brushless type portable generator will need Note: Some Rotors have a magnet placed inside
4 major components to function—a prime mover, a to help excite the rotor after it has been left idle
stator, a rotor, and a capacitor. for a long period of time.
As the engine starts to crank, residual magnetism
from the rotor creates magnetic lines of flux. The
lines begin to cut the excitation winding and induce DIODE A
a small voltage into the winding. The voltage causes
the capacitor to charge. When the capacitor has fully
charged it will discharge a voltage that will be induced
back into the rotor. The AC voltage induced into the COIL 1
rotor is rectified using a diode. The magnetic lines of

flux from the rotor will increase, causing output volt-
age to increase. The charge and discharge relation-
ship that the capacitor and rotor share is the voltage
regulation system that allows the generator to main-
tain 240 volts. COIL 2
Figure 1 shows the major components of a typical GP
Series brushless AC generator.
DIODE B
ENGINE
Figure 2. Rotor and Diodes
Circuit Breakers
CAPACITOR
Each individual circuit on the generator is protected
by a circuit breaker to prevent overload.
ROTOR TO LOAD
MLB = MAIN LINE
CIRCUIT BREAKER
MLB
STATOR
240 VAC
120 VAC 120 VAC
Figure 1. AC Generator Exploded View

STATOR STATOR
POWER POWER
WINDING WINDING
Stator Assembly
MAGNETIC
The stator has three windings wound separately FIELD
inside the can. Two are the power windings and are
located on Wire 44 (Hot) and Wire 33 (Neutral), the ENGINE -
other winding is located on Wire 11 (Hot) and Wire 22 DIRECT ROTOR
(Neutral). The third winding is called the DPE winding DRIVE
or Displaced Phase Excitation winding and is located
on Wire 2 and Wire 6. MAGNETIC
FIELD
Rotor Assembly STATOR

EXCITATION
The 2-pole rotor must be operated at 3600 rpm to WINDING
supply a 60 Hertz AC frequency. The term “2-pole”
means the rotor has a single north magnetic pole and
a single south magnetic pole. It spins freely inside
CAPACITOR
the stator can and is excited by the charging and dis-
charging of the capacitor. It has two diodes that rec-
tify voltage induced from the Excitation winding to DC A CAPACITIVE DISCHARGE B
voltage. The rotor bearing is pressed onto the end of Figure 3. Generator Operating Diagram
the rotor shaft. The tapered rotor shaft is mounted to
Page 16
Section 1.3
BRUSHLESS, CAPACITOR EXCITATION SYSTEM
Operation FIELD EXCITATION:

An AC voltage is induced into the stator excitation
STARTUP: (DPE) windings. The DPE winding circuit is completed
to the capacitor where the charging and discharging
When the engine is started, residual magnetism from causes a voltage to be induced back in to the rotor
the rotor induces a voltage into (a) the stator AC which will regulate voltage. The greater the current
power windings, (b) the stator excitation or DPE wind- flow through the rotor windings, the more concen-
ings. In an “On-speed” (engine cranking) condition, trated the lines of flux around the rotor become. The
residual magnetism is capable of creating approxi- more concentrated the lines of flux around the rotor
mately one to three Volts AC. that cut across the stationary stator windings, the
greater the voltage that is induced into the stator
ON-SPEED OPERATION: windings. Initially, the AC power winding voltage is
As the engine accelerates, the voltage that is induced low, but as the capacitor is charged and discharged
into the stator windings increases rapidly, due to the this relationship between the rotor and the capacitor
increasing speed at which the rotor operates. is what will regulate voltage at a desired level.
AC POWER WINDING OUTPUT:

CAPACITOR 47µf (440 VAC)
WIRE 6
A regulated voltage is induced into the stator AC
power windings. When electrical loads are connected
across the AC power windings to complete the circuit,
current can flow in the circuit.
WIRE 2
11 22 33 44
A
Figure 4. Alternator Configuration A
RED (R2 – 33)
BLUE (R1 – 44)

BROWN (L2 – 22)
WHITE (L1 – 11)
WIRE 6
CAPACITOR 28µf
WIRE 2
B
Figure 5. Alternator Configuration B
Page 17
Section 1.4
BRUSHED EXCITATION SYSTEM
Introduction to the negative (-) slip ring and brush on Wire 0. This
current flow creates a magnetic field around the rotor
A typical brushed type portable generator will need 4 having a flux concentration that is proportional to the
major components to function: a prime mover, a sta- amount of current flow.
tor, a rotor, and a voltage regulator.
As the engine starts to crank, residual magnetism
from the rotor creates magnetic lines of flux. The lines Rotor Residual Magnetism
begin to cut the excitation winding and induce a small
voltage into the voltage regulator. The excitation volt- The generator revolving field (rotor) may be consid-
age will power the voltage regulator and the voltage ered to be a permanent magnet. Some “residual”
regulator will start to sense AC voltage from Wires magnetism is always present in the rotor. This residu-
S15 and S16. The lower voltage from the sensing al magnetism is sufficient to induce a voltage into the
wires will cause DC excitation to the rotor to be driven stator AC power windings that is approximately 2-5
up until AC output is at desired level of 240VAC. Once volts AC.
the generator has reached 240VAC it will maintain the Note: Some Rotors have a magnet placed inside
DC voltage, regulating the alternator when loads are to help excite the rotor after it has been left idle
applied and removed. for a long period of time.
ENGINE Voltage Regulator

Refer to Figure 3 for the proper identification of the
voltage regulator. Unregulated AC output from the
stator excitation winding is delivered to the regulator’s
BRUSHES DPE terminals, via Wire 2 and Wire 6. The voltage
regulator rectifies that current and, based on stator
AC power winding sensing, regulates it. The rectified
and regulated excitation current is then delivered to
the rotor windings from the positive (+) and negative
(-) regulator terminals, via Wire 4 and Wire 0. Stator
ROTOR
AC power winding “sensing” is delivered to the regula-
tor via Wires S15 and S16.
Operation
STATOR
STARTUP:
When the engine is started, residual magnetism from
VOLTAGE REGULATOR the rotor induces a voltage into (a) the stator AC
power windings, (b) the stator excitation or DPE wind-
ings. In an “on-speed” (engine cranking) condition,
Figure 1. AC Generator Exploded View residual magnetism is capable of creating approxi-
mately one to three volts AC.
Stator Assembly ON-SPEED OPERATION:

As the engine accelerates, the voltage that is induced
The stator has three windings wound separately into the stator windings increases rapidly, due to the
inside the can. Two are the power windings and are increasing speed at which the rotor operates.
located on Wire 44 (Hot) and Wire 33 (Neutral); the
other winding is located on Wire 11 (Hot) and Wire 22 FIELD EXCITATION:
(neutral). The third winding is called DPE winding or
Displaced Phase Excitation winding and is located on An AC voltage is induced into the stator excitation
Wire 2 and Wire 6. (DPE) windings. The DPE winding circuit is com-
pleted to the voltage regulator, via Wire 2 and Wire
6. Unregulated alternating current can flow from the
Brush Holder and Brushes winding to the regulator. The voltage regulator “sens-
es” AC power winding output voltage and frequency
The brush holder is retained to the rear bearing car- via stator Wires S15 and S16.
rier by means of two Taptite screws. A positive (+) and The regulator changes the AC from the excitation
a negative (-) brush are retained in the brush holder. winding to DC. In addition, based on the Wire S15
Wire 4 connects to the positive (+) brush and Wire and Wire S16 sensing signals, it regulates the flow of
0 to the negative (-) brush. Rectified and regulated direct current to the rotor. The rectified and regulated
excitation current are delivered to the rotor windings current flow from the regulator is delivered to the rotor
via Wire 4, and the positive (+) brush and slip ring. windings, via Wire 4, and the positive brush and slip
The excitation current passes through the windings ring. This excitation current flows through the rotor
Page 18
Section 1.4
BRUSHED EXCITATION SYSTEM
windings and through the negative (-) slip ring and

brush on Wire 0. TO LOAD TO LOAD
TheMLB greater the current

= MAIN LINE
MLBflow through the rotor wind-
MLB = MAIN LINE
MLB
CIRCUIT
ings, the BREAKER
more concentrated the lines of flux around CIRCUIT BREAKER
the rotor become. The more concentrated the lines
240 VAC 240 VAC
of flux around the rotor that
120 VAC
cut across the stationary
120 VAC 120 VAC 120 VAC SENSING
stator windings, the greater the voltage that is induced
into the stator windings.
STATOR STATOR STATOR STATOR
Initially, the AC power winding voltage sensed by the
POWER POWER POWER POWER
regulator is WINDING
low. The regulatorWINDING
reacts by increasing WINDING WINDING
the flow of excitation current to the rotor until volt-
age increases to a MAGNETICdesired level. The regulator then MAGNETIC
maintains the desiredFIELD voltage. For example, if voltage FIELD
exceeds the desired level, the regulator will decrease
theENGINE
flow of- excitation current. Conversely, if voltage ENGINE -
drops
DIRECTbelow the desired ROTORlevel, the regulator responds DIRECT ROTOR - +
byDRIVE
increasing the flow of excitation current. DRIVE
AC POWER WINDINGMAGNETIC
OUTPUT: MAGNETIC
FIELD FIELD
A regulated voltage is induced into the stator AC
power windings. When electrical loads are connected
STATOR STATOR AUTOMATIC
across the AC power windings to complete the circuit,
EXCITATION EXCITATION VOLTAGE
current can flow in the circuit.
WINDING WINDING REGULATOR
CAPACITOR Figure 2. 240 VAC Sensing Alternator
A CAPACITIVE DISCHARGE B DIRECT EXCITATION

WHITE S15 2 BLUE
C1 FEMALE AVR SENSING DPE
GREEN S16 6 BLUE
4 (+) RED
NOT USED
0 (-) WHITE
C1 MALE
RED (R2 – 11)
BLUE (R1 – 22)

BROWN (L2 – 33)
WHITE (L1 – 44)
VOLTAGE REGULATOR
C
Figure 3. Alternator Configuration C
Page 19
NOTES
Page 20
Table of contents
Part Title Page#
2.1 Brushless Excitation 22

Troubleshooting Flowcharts
PART 2
2.2 Brushed Capacitor 24
Troubleshooting Flowcharts
AC GENERATORS
2.3 AC Diagnostic Tests 26
Part 2 – AC Generators.......................................... 21 Test 4 – Field Flash Alternator

(Configuration “A” Only)........................27
Section 2.1 – Brushless Capacitor
Troubleshooting Flowcharts.............. 22 Test 5 – Check Brushed Rotor Circuit...............28
Section 2.2 – Brushed Excitation Test 6 – Check Capacitor..................................29
Troubleshooting Flowcharts.............. 24 Test 7 – Test Brushless DPE Winding...............30
Section 2.3 – AC Diagnostic Tests......................... 26 Test 8 – Test Brushless Stator Windings...........30
Introduction.......................................................26 Test 9 – Test Brushed Stator Windings.............31
Test 1 – Check No-Load Voltage Test 10 – Check Load Voltage & Frequency.....31
and Frequency.....................................26
Test 11 – Check Load Watts & Amperage........31
Test 2 – Check Circuit Breaker.........................26
Test 12 – Adjust Voltage Regulator...................31
Receptacle Panel.................................26
Page 21
Section 2.1
Part 2 AC generators
Brushless Capacitor Troubleshooting flowcharts
The GP series portable generators currently use Identify the configuration of the alternator being ser-
three different types of alternators. Two of the alterna- viced using Sections 1.3 and 1.4 of this manual and
tors are brushless capacitor type with different style of proceed to the appropriate flowchart section.
capacitors (Configuration “A” and “B”). The third uti- Configuration “A” – Brushless Capacitor, use Section 2.1
lizes a voltage regulator and a brushed excitation sys-
tem (Configuration “C”). To help with troubleshooting, Configuration “B” – Brushless Capacitor, use Section 2.1
two sets of flow charts have been created for these Configuration “C” – Brushed Excitation, use Section 2.2
different styles of alternators.
If Problem Involves AC Output

TEST 1 - CHECK
NO LOAD VOLTAGE
& FREQUENCY
VOLTAGE & FREQUENCY GOOD FREQUENCY GOOD, ZERO VOLTAGE NO LOAD VOLTAGE &
FREQUENCY BOTH VOLTAGE HIGH LOW OR RESIDUAL ZERO FREQUENCY FREQUENCY GOOD -
HIGH OR LOW VOLTAGE VOLTAGE/FREQUENCY
FALLS OFF UNDER LOAD
GO TO PROBLEM 2 GO TO PROBLEM 4 GO TO PROBLEM 1 VERIFY ROTOR IS SPINNING, GO TO PROBLEM 3

GO TO PROBLEM 1
Problem 1 – Generator Produces Zero Voltage or Residual Voltage

GOOD
TEST 2 – CHECK TEST 3 – CHECK TEST 4 – FIELD
CONFIGURATION “A”
MAIN CIRCUIT ON CONTINUITY OF FLASH
BREAKER RECEPTACLE PANEL ALTERNATOR
BAD
GOOD RE-CHECK VOLTAGE
CONFIGURATION “B” AT RECEPTACLE
RESET TO “ON” PANEL
OR REPLACE IF BAD REPLACE COMPONENT
AS NEEDED
GOOD
GOOD TEST STATOR
FOR SHORTS BAD
REPLACE BAD TO GROUND
ALTERNATOR STOP
TESTING
TEST 8 – TEST TEST 6 –

TEST 7 – TEST
REPLACE BRUSHLESS
GOOD GOOD BRUSHLESS GOOD CHECK
CAPACITOR STATOR
DPE WINDING CAPACITOR
WINDINGS
BAD BAD
BAD
REPLACE REPLACE
STATOR
RE-CHECK VOLTAGE
AT RECEPTACLE GOOD STOP TESTING
PANEL
BAD REPLACE
CONFIGURATION “A” ROTOR
BAD REPLACE
CONFIGURATION “B” ALTERNATOR
Page 22
Section 2.1
AC generators Part 2
Brushless Capacitor Troubleshooting flowcharts
Problem 2 – Voltage & Frequency Are Both High or Low
FREQUENCY GOOD, LOW OR GO TO

RESIDUAL VOLTAGE PROBLEM 1
TEST 40 – CHECK & ADJUST ENGINE
GOVERNOR, 389cc ENGINE
NO-LOAD FREQUENCY & VOLTAGE GOOD BUT GO TO
THEY DROOP TO MUCH WHEN LOAD IS APPLIED PROBLEM 3
GO TO PROBLEM 1,
FREQUENCY IS GOOD BUT TEST 6 – CHECK
CONFIGURATION “A”
REPLACE NO-LOAD VOLTAGE IS HIGH CAPACITOR
ALTERNATOR
BAD CONFIGURATION “B”
RE-CHECK VOLTAGE
STOP REPLACE
GOOD AT RECEPTACLE
TESTING CAPACITOR
PANEL
Problem 3 – Excessive Voltage/Frequency Droop When Load is Applied
TEST 10 – CHECK TEST 11 – CHECK

LOAD VOLTAGE & BAD LOAD WATTS & NOT OVERLOADED
FREQUENCY AMPERAGE
GOOD OVERLOADED REDUCE LOAD
END TEST
& ADJUST & ADJUST
GO TO PROBLEM 12 GOOD ENGINE ENGINE GOOD GO TO PROBLEM 23
GOVERNOR, GOVERNOR,
389cc ENGINE 410cc ENGINE
Problem 4 – Generator Produces High Voltage at No-Load

TEST 1 – CHECK GOVERNOR, 389cc ENGINE
NO-LOAD VOLTAGE FREQUENCY FREQUENCY AND STOP
AND FREQUENCY HIGH VOLTAGE O.K. TESTS
FREQUENCY O.K.,
BUT VOLTAGE HIGH
TEST 6 – GO TO “PROBLEM 1”,

FREQUENCY O.K., BUT
CHECK GOOD CONFIGURATION “A” TEST 7 – TEST BRUSHLESS
VOLTAGE IS STILL HIGH
CAPACITOR DPE WINDING
BAD CONFIGURATION “B” REPLACE

BAD
ALTERNATOR
REPLACE REPLACE RE-CHECK VOLTAGE AT STOP

CAPACITOR RECEPTACLE PANEL GOOD
TESTING
Page 23
Section 2.2
Brushed Excitation Troubleshooting flowcharts
The GP series portable generators currently use Identify the configuration of the alternator being ser-
three different types of alternators. Two of the alterna- viced using Sections 1.3 and 1.4 of this manual and
tors are brushless capacitor type with different style of proceed to the appropriate flowchart section.
capacitors (Configuration “A” and “B”). The third uti- Configuration “A” – Brushless Capacitor, use Section 2.1
lizes a voltage regulator and a brushed excitation sys-
tem (Configuration “C”). To help with troubleshooting, Configuration “B” – Brushless Capacitor, use Section 2.1
two sets of flow charts have been created for these Configuration “C” – Brushed Excitation, use Section 2.2
different styles of alternators.
If Problem Involves AC Output

TEST 1 - CHECK
NO LOAD VOLTAGE
& FREQUENCY
VOLTAGE & FREQUENCY GOOD FREQUENCY GOOD, ZERO VOLTAGE NO LOAD VOLTAGE &
FREQUENCY BOTH VOLTAGE HIGH LOW OR RESIDUAL ZERO FREQUENCY FREQUENCY GOOD -
HIGH OR LOW VOLTAGE VOLTAGE/FREQUENCY
FALLS OFF UNDER LOAD
GO TO PROBLEM 6 GO TO PROBLEM 5 GO TO PROBLEM 5 VERIFY ROTOR IS SPINNING, GO TO PROBLEM 7

GO TO PROBLEM 5
Problem 5 – Generator Produces Zero Voltage or Residual Voltage
TEST 2 – CHECK TEST 3 – CHECK TEST 12 – ADJUST

MAIN CIRCUIT ON CONTINUITY OF GOOD AUTOMATIC VOLTAGE BAD
BREAKER RECEPTACLE PANEL REGULATOR
BAD GOOD
RESET TO “ON”
OR REPLACE IF BAD REPLACE COMPONENT STOP TESTING
AS NEEDED
REPLACE BAD TEST 5 – CHECK

BRUSHES BRUSHES
REPLACE RE-CHECK VOLTAGE

REPLACE AUTOMATIC
ALTERNATOR BAD AT RECEPTACLE GOOD
VOLTAGE REGULATOR
PANEL
GOOD
STOP TESTING
Page 24
Section 2.4
Brushed Excitation Troubleshooting flowcharts
Problem 6 – Voltage & Frequency Are Both High or Low
FREQUENCY GOOD, GO TO
LOW OR RESIDUAL PROBLEM 5
VOLTAGE

GOVERNOR, 389cc ENGINE NO-LOAD FREQUENCY &
VOLTAGE GOOD BUT THEY GO TO
DROOP TO MUCH WHEN PROBLEM 7
LOAD IS APPLIED
FREQUENCY IS GOOD GO TO PROBLEM 5,

BUT NO-LOAD TEST 12 – ADJUST
VOLTAGE IS HIGH VOLTAGE
REGULATOR
Problem 7 – Excessive Voltage/Frequency Droop When Load is Applied

LOAD VOLTAGE & BAD LOAD WATTS & NOT OVERLOADED
FREQUENCY AMPERAGE
GOOD OVERLOADED REDUCE LOAD
END TEST

& ADJUST & ADJUST
GO TO PROBLEM 12 GOOD ENGINE ENGINE GOOD GO TO PROBLEM 23
GOVERNOR, GOVERNOR,
389cc ENGINE 410cc ENGINE
Problem 8 – Generator Produces High Voltage at No-Load
TEST 1 – CHECK TEST 40 – CHECK & ADJUST ENGINE

FREQUENCY GOVERNOR, 389cc ENGINE
NO-LOAD VOLTAGE
HIGH
AND FREQUENCY
TEST 41 – CHECK & ADJUST ENGINE FREQUENCY AND
GOVERNOR, 410cc ENGINE VOLTAGE O.K.
FREQUENCY O.K.,
BUT VOLTAGE HIGH
TEST 12 – ADJUST
AUTOMATIC VOLTAGE STOP
REGULATOR REPLACE BAD TESTS
ALTERNATOR
FREQUENCY O.K., REPLACE AUTOMATIC RE-CHECK VOLTAGE

BUT VOLTAGE IS VOLTAGE REGULATOR AT RECEPTACLE GOOD
STILL HIGH PANEL
Page 25
Section 2.3
AC Diagnostic tests
Introduction TEST 2 – CHECK CIRCUIT BREAKER

The “Diagnostic Tests” in this chapter may be per-
formed in conjunction with the “Flow Charts” of PROCEDURE:
Section 2.1 and Section 2.2. Test numbers in this The generator has circuit breakers located on the
chapter correspond to the numbered tests in the control panel. If outlets are not receiving power, make
“Flow Charts”. It may be helpful to read Section 1.2, sure the breakers are set to ON or “Closed”.
“Measuring Electricity.” If a breaker is suspected to have failed, it can be
NOTE: Test procedures in this Manual are not nec- tested as follows:
essarily the only acceptable methods for diagnos-
ing the condition of components and circuits. All 1. Set a VOM to measure resistance.
possible methods that might be used for system 2. With the generator shut down, disconnect all wires from the
diagnosis have not been evaluated. If any diag-
nostic method is used other than the method pre- suspected circuit breaker terminals to prevent interaction.
sented in this Manual, the technician must ensure 3. With the generator shut down, connect one meter test
that neither his personal safety nor the product's
safety will be endangered by the procedure or lead to a one terminal of the breaker and the other
method that has been selected. meter test lead to the other terminal. See Figure 2.
For visual pictures of the different configurations 4. Set the breaker to its ON or “Closed” position. The meter
of the stators and the wire numbers associated should read CONTINUITY.
with different components please see Figures 4
and 5 in Section 1.3, and Figure 3 in Section 1.4. 5. Set the breaker to its OFF or “Open” position and the
meter should indicate INFINITY.
Test 1 – Check No-Load Voltage and
Frequency
20/30A
PROCEDURE: 00.01 C.B.
1. Disconnect or turn OFF all electrical loads connected to
the generator.
2. Set a VOM to measure AC voltage.
3. Reset all circuit breakers to the on position.
4. Start the engine and let it stabilize and warm up.
Figure 2. 20/30 Amp Breaker Test Points
240 RESULTS:
1. If the circuit breaker tests good, refer back to the flow
chart.
2. If the breaker tests bad, it should be replaced.

Figure 1. VOM Test Leads Connected to a 240 VAC Receptacle Panel
receptacle
Discussion:
6. Place the meter test leads into an outlet. See Figure 1. Continuity of the receptacle panel is important
7. Read the AC voltage. because it reflects that the receptacle has continuity
through the wiring and is physically connected to the
8. Connect a AC frequency meter as described in Step 6. stator. Most stator winding values are between 0.01
and 0.02 Ohms of resistance. If a higher than normal
9. Read the AC frequency. ohm reading is shown then a poor connection could
be the problem preventing that receptacle from receiv-
RESULTS: ing power.
No Load Voltage No Load Frequency Procedure:
223.2 – 256.8 VAC 62.5 – 62.0 HZ
1. Set a VOM to measure Resistance.
Refer back to Flow Chart.
Page 26
Section 2.3
AC Diagnostic tests
2. Connect a VOM as shown in Figure 3 to each receptacle Test 4 – Field Flash Alternator
on the unit. (Configuration “A” Only)
Note: Only one outlet on each receptacle needs to Discussion:
be tested.
The alternator utilizes residual magnetism within the
Results: windings to charge the capacitor. If the generator has
been sitting for a long period of time with no activity
1. If any other reading than continuity was measured fur- the residual magnetism could be lost within the rotor.
ther troubleshooting will need to be done to determine if Field flashing the rotor while connected in parallel with
it is the receptacle or the wiring. the capacitor will force a charge of electricity through
the DPE winding. The voltage that is induced into the
2. If receptacles test good, refer back to flow chart. rotor will in turn charge the rotor with enough residual
magnetism that it will be able to charge the capacitor
during normal operation.
Warning: Please keep safety in mind while
0.01 Ohms
* performing this test.
Procedure:
1. Construct an energizing cord that is similar to that shown
in Figure 4 and connect it as shown in Figure 5 on the
next page.
2. Set the START-RUN-STOP switch to the OFF position.
Warning: Do NOT energize the capacitor for
* more than 1 second at a time.
3. Momentarily turn on the energizing cord (one second).
4. Disconnect the energizing cord from the capacitor.
5. If the field flash was successful, the generator should now
be producing approximately 240 VAC at the main circuit
Figure 3. Checking Continuity of Receptacles breaker of the generator when the START-RUN-STOP is
set to the START position.
MOMENTARY PUSHBUTTON ON/OFF SWITCH

SINGLE POLE SWITCH ON LIVE SIDE
 DO NOT SUBSTITUTE ANY OTHER DEVICE
12 AWG 12 AWG
4 ft.
STANDARD
MALE PLUG
CRIMP ON STANDARD
FEMALE BLADE
CONNECTORS
Figure 4. Construction of Energizing Cord
Page 27
Section 2.3
AC Diagnostic tests
PLUG ENERGIZING CORD DEPRESS SWITCH FOR

INTO AC OUTLET ONE SECOND
CAPACITOR
CAPICITOR REMAINS CONNECTED

TO GENERATOR
 discharged
Danger: The capacitor may need to be
before testing. A capacitor can
be discharged by crossing the terminals
with a metal insulated screw driver.
Danger: Use proper protective equipment

 when dealing with a capacitor that has
exploded.
Figure 5. Connecting Energizing Cord
Warning: Do not field flash alternator more 3. Inspect the rotor slip rings. If they appear dull or tar-
* than two times in sequence. If the unit has
not produced power after two attempts, other
nished, they may be polished with fine sandpaper. DO
NOT USE METALLIC GRIT TO POLISH SLIP RINGS.
issues exist and need to be addressed.
Results:
1. Refer back to flow chart. + –
Test 5 – Check Brushes
DISCUSSION:
The function of the brushes and slip rings is to pro-
vide passage of excitation current from stationary
components to the rotating rotor. Brushes are made
of a special long lasting material and seldom wear
out or fail. However, slip rings can develop a tarnish or
film that can inhibit or offer a resistance to the flow of
electricity. Such a non-conducting film usually devel-
ops during non-operating periods. Broken or discon- Figure 6. Brushes and Slip Rings
nected wiring can also cause loss of excitation current
to the rotor.
Results:
PROCEDURE: 1. Repair, replace or reconnect wires as necessary.
1. See Figure 6. Carefully inspect brush wires. Make sure 2. Replace any damaged slip rings or brush holder.
they are properly and securely connected.
3. Clean and polish slip rings as required.
2. Disconnect the red and white wire from the brush assem-
4. If brush assembly and slip rings look good proceed to
bly. Remove the brush assembly from the bearing car-
Step 5.
rier. Inspect the brushes for excessive wear, or damage.
Page 28
Section 2.3
AC Diagnostic tests
Test 6 – Check Capacitor

SET TO READ
CAPACITANCE
DISCUSSION:
The brushless rotor system relies on the charging and 59.0 µf
discharging of a capacitor to induce voltage into the
rotor and also to regulate voltage once 240 VAC is
achieved. If the capacitor fails, only residual magne-
tism of the rotor will be measured at the Main Breaker.
Warning: The capacitor may need to be dis-

* charged before testing. A capacitor can be
discharged by crossing the terminals with a
metal insulated screw driver.
Warning: Use proper protective equipment

* when dealing with a capacitor that has
exploded.
PROCEDURE:
1. Consult the owner’s manual of the meter being used for
directions on measuring capacitance. Figures 7 and 8
show a typical meter and how to check capacitance.
2. Connect the meter leads directly across the terminals of
the capacitor. The rated µf (micro farad) of the capacitor Figure 7. Capacitor Test Points
is marked on the side of the canister. (Alternator Configuration “A”)
3. The meter should display the correct µf reading ± 5µf.
If anything other than the indicated rating is displayed,
SET TO READ
replace the capacitor. CAPACITANCE
RESULTS: 28.0 µf
1. Refer back to flow chart
2. Common observations can be made by visually inspect-
ing the capacitor.
a. A capacitor that has gone bad can have a ten- CAPACITOR 28µf
dency to explode. Use caution when dealing
with an exploded capacitor, the gel from inside
a capacitor can cause skin irritation.
b. A capacitor is defective if the terminal connec-
tions are loose on the canister.
c. A capacitor is defective if it wobbles while sitting
on a flat surface.
d. If any of the above observations are observed,
replace the capacitor.
Figure 8. Capacitor Test Points

(Alternator Configuration “B”)
Page 29
Section 2.3
AC Diagnostic tests
Test 7 – Test Brushless DPE Winding Test 8 – Test Brushless Stator Windings
DISCUSSION: DISCUSSION:
A DPE or Displaced Phase Excitation winding is used The brushless stator has three internal windings,
to charge a capacitor, which discharges and charges, two main power windings and a DPE winding. This
releasing a voltage that is induced into the rotor. If test will ensure that there are no shorts between the
the DPE winding fails, only residual magnetism of the power windings or shorts to ground.
rotor will be measured at the Main Breaker. A VOM meter can be used to test the stator windings
Note: The resistance of stator windings is very for the following faults:
low. Some meters will not read such a low resis- • An open circuit condition
tance, and will simply indicate CONTINUITY. • A “short-to-ground” condition
Recommended is a high quality, digital type meter
capable of reading very low resistances. • A short circuit between windings
Note: The resistance of stator windings is very
Danger: The capacitor may need to be dis-
*
low. Some meters will not read such a low resis-
charged before testing. A capacitor can be tance, and will simply indicate CONTINUITY.
discharged by crossing the terminals with Recommended is a high quality, digital type meter
a metal insulated screw driver. capable of reading very low resistances.
Note: Refer to Figure 4 in Section 1.3 for illustra-
tion of Stator Configuration “A”. Some wire num-
PROCEDURE: bers will not be marked on the stator.
1. Disconnect Wire 2 and Wire 6 from the capacitor.
PROCEDURE:
2. Set VOM to measure resistance.
1. Disconnect Wires 11, 22, 33, 44 from the receptacle
3. Connect one meter lead to Wire 2 and connect the other panel so that the stator is isolated.
meter lead to Wire 6.
2. Make sure all of the disconnected leads are isolated
a. Reading should be approximately 0.97 and 1.13 from each other and are not touching the frame during
Ohms.
the test.
4. Connect one meter lead to Wire 2 and connect the other
meter lead to a clean frame ground, INFINITY should be 3. Set a VOM to measure resistance.
measured. 4. Connect one test lead to Stator Lead 11. Connect the
5. Isolate the stator wire so that the stator is disconnected other test lead to Stator Lead 22. Stator resistance
from the receptacle panel and the capacitor. should be between 0.12-0.14 Ohms.
Note: Isolate all main stator leads before proceeding. 5. Connect one test lead to Stator Lead 33. Connect the
other test lead to Stator Lead 44. Stator resistance
6. Connect one meter lead to Wire 2 and connect the other
should be between 0.12-0.14 Ohms.
meter lead to Wire 11. INFINITY should be measured.
7. Repeat Step 6 using Wire 2 and Wire 44.INFINITY Test windings for a short to ground:
should be measured. 1. Make sure all leads are isolated from each other and are
Results: not touching the frame.
1. Stator winding resistance values is a test of winding conti- 2. Connect one test lead to a clean frame ground. Connect
nuity and resistance. If a very high resistance or INFINITY the other test lead to Stator Lead Wire 11.
is indicated, the winding is open or partially open. a. The meter should read INFINITY.
2. Testing for a “grounded” condition: Any resistance read- b. Any reading other than INFINITY indicates a
ing indicates that the winding is grounded. “short to ground” condition.
3. Repeat Step 2 using Stator Lead 44
3. Testing for a “shorted” condition: Any resistance reading
indicates that the winding is shorted. Test for a short circuit between windings:
4. If stator tests good and wire continuity tests good, refer 1. Connect one test lead to Stator Lead 11. Connect the
back to flow chart. other test lead to Stator Lead 33.
a. The meter should read INFINITY.
b. Any reading other that INFINITY indicates a
short between windings.
Page 30
Section 2.3
AC Diagnostic tests
Test 9 – Test Brushed Stator Windings RESULTS:

1. If the unit is overloaded, reduce the load.
DISCUSSION:
2. If load is within limits, but frequency and voltage still drop
Most brushed stators have three main windings that
are needed to produce voltage. The alternator has excessively, refer back to Flow Chart.
two main power windings that supply power to the Overloading a generator in excess of its rated wattage
load and a DPE winding to provide excitation voltage capacity can result in damage to the generator and to
to the rotor. It is important that these windings remain connected electrical devices. Observe the following to
isolated from ground or the chassis of the alternator. prevent overloading the unit:
• Add up the total wattage of all electrical devices to
Procedure: be connected at one time. This total should NOT be
1. Isolate all stator wires from the control panel and the greater than the generator's wattage capacity.
voltage regulator. • The rated wattage of lights can be taken from light
bulbs. The rated wattage of tools, appliances and
2. Set a VOM to measure resistance. motors can usually be found on a data label or
decal affixed to the device.
3. Refer to Configuration “C” in Section 1.4 for proper test
• If the appliance, tool or motor does not give watt-
points for checking the stator. Every connection needs to age, multiply volts times ampere rating to determine
be checked coming out of the stator for a short to ground. watts (volts x amps = watts).
• Some electric motors, such as induction types,
Results: require about three times more watts of power for
1. If any wire has a direct short to ground or to the chassis starting than for running. This surge of power lasts
only a few seconds when starting such motors.
of the alternator replace the alternator assembly.
Make sure to allow for high starting wattage when
2. If all wires test good for a short to ground, refer back to selecting electrical devices to connect to the generator:
flow chart. 1. Figure the watts needed to start the largest motor.
2. Add to that figure the running watts of all other con-
Test 10 – Check Load Voltage & nected loads.
Frequency
Test 12 – Adjust Voltage Regulator
PROCEDURE:
Perform this test in the same manner as Test 1, but
apply a load to the generator equal to its rated capacity. Procedure:
With load applied check voltage and frequency. 1. Remove cover from end of alternator assembly.
Frequency should not drop below about 59 Hertz with 2. Remove two screws holding down the voltage regulator
the load applied.
(AVR); refer to Figure C in Section 1.4 for identification.
Voltage should not drop below about 220 VAC nor rise
above 265 VAC with load applied. 3. Leave AVR connected to stator and brushes
RESULTS: 4. Set VOM to measure AC voltage.
1. If voltage and/or frequency drop excessively when the 5. Connect VOM across a 240VAC socket as shown in
load is applied, refer back to flow chart. Figure 9.
2. If load voltage and frequency are within limits, end tests.
Test 11 – Check Load Watts & Amperage 240
PROCEDURE:
Add up the wattages or amperages of all loads pow-
ered by the generator at one time. If desired, a clamp-
on ammeter may be used to measure current flow.
See “Measuring Current” in Section 1.2.
A Wattage Reference Guide is provided on the next
page to assist in determining how many items the
generator can operate at one time. Figure 9. VOM Test Leads Connected to a 240 VAC
NOTE: All figures are approximate. See data label receptacle
on appliance for wattage requirements.
Page 31
Section 2.3
AC Diagnostic tests
6. Ensure all material is clear of the alternator before pro-

ceeding.
7. Set START-STOP-RUN switch to START
8. Refer to Figure 10 for location of adjustment screw.
9. Adjusting screw clockwise will increase voltage, adjust-
ing counterclockwise will lower the voltage.
Results:
1. If no change in voltage while adjusting refer back to flow
chart.
2. If voltage is correct, stop testing.
Figure 10. Voltage Regulator Adjustment Screw
Wattage Reference Guide

Device Running Device Running
Watts Watts
*Air Conditioner (12,000 Btu) 1700 Hand Drill 250 to 1100
*Air Conditioner (24,000 Btu) 3800 Hedge Trimmer 450
*Air Conditioner (40,000 Btu) 6000 Impact Wrench 500
Battery Charger (20 Amp) 500 Iron 1200
Belt Sander (3") 1000 *Jet Pump 800
Chain Saw 1200 Lawn Mower 1200
Circular Saw (6-1/2") 800 to 1000 Light Bulb 100
*Clothes Dryer (Electric) 5750 Microwave Oven 700 to 1000
*Clothes Dryer (Gas) 700 *Milk Cooler 1100
*Clothes Washer 1150 Oil Burner on Furnace 300
Coffee Maker 1750 Oil Fired Space Heater (140,000 Btu) 400
*Compressor (1 HP) 2000 Oil Fired Space Heater (85,000 Btu) 225
*Compressor (3/4 HP) 1800 Oil Fired Space Heater (30,000 Btu) 150
*Compressor (1/2 HP) 1400 *Paint Sprayer, Airless (1/3 HP) 600
Curling Iron 700 Paint Sprayer, Airless (handheld) 150
*Dehumidifier 650 Radio 50 to 200
Disc Sander (9") 1200 *Refrigerator 700
Edge Trimmer 500 Slow Cooker 200
Electric Blanket 400 *Submersible Pump (1-1/2 HP) 2800
Electric Nail Gun 1200 *Submersible Pump (1 HP) 2000
Electric Range (per element) 1500 *Submersible Pump (1/2 HP) 1500
Electric Skillet 1250 *Sump Pump 800 to 1050
*Freezer 700 *Table Saw (10") 1750 to 2000
*Furnace Fan (3/5 HP) 875 Television 200 to 500
*Garage Door Opener 500 to 750 Toaster 1000 to 1650
Hair Dryer 1200 Weed Trimmer 500
* Allow 3 times the listed watts for starting these devices.
Page 32
Table of contents
Part Title Page#
3.1 389/206/163cc Troubleshooting 34

PART 3 Flow Charts
3.2 410cc Troubleshooting Flow 37
ENGINE Charts
3.3 Diagnostic Tests 42
TROUBLESHOOTING
Part 3 – Engine Troubleshooting........................... 33 Test 30 – Choke Test.........................................47

Section 3.1 – 389/206/163cc Troubleshooting Test 33 – Check Valve Adjustment....................47
Flowcharts........................................ 34 Test 36 – Check Engine / Cylinder Leak Down
Section 3.2 – 410cc Troubleshooting Flowcharts... 37 Test / Compression Test.......................48
Section 3.3 – Diagnostic Tests............................... 42 Test 38 – Check Flywheel.................................48
Test 20 – Check 1.5 Amp Fuse.........................42 Test 39 – Remove Wire 18 / Shutdown Lead....49
Test 21 – Check Battery & Cables....................42 Test 40 – Check / Adjust Governor
(389cc Engine).....................................49
Test 22 – Check Voltage at
Starter Contactor (SC).........................42 Test 41 – Check / Adjust Governor
(410cc Engine).....................................50
Test 23 – Check Start-Run-Stop Switch...........42
Test 45 – Check Oil Level Switch......................51
Test 24 – Test OFF-ON Switch..........................43
Test 46 – Check Oil Pressure Switch................51
Test 25 – Check Starter Motor..........................43
Test 49 – Test Recoil Function..........................52
Test 25 – Check Ignition Spark.........................45
Test 50 – Test Engine Function.........................52
Test 26 – Check Spark Plugs............................46
Test 29 – Check Carburetion............................46
Page 33
Section 3.1
Part 3 ENGINE TROUBLESHOOTING
389/206/163cc Troubleshooting flow charts
There are 4 different types of engines on the GP Series The Specifications section at the front of this manual
generators: 410cc, 389cc, 206cc, 163cc. Section 3 is provides details about engine displacement for the vari-
divided into difference subsections that provide engine ous GP Series generators.
troubleshooting for each type of engine. It is imperative 389cc, 206cc and 163cc Engines, use Section 3.1
to identify what type of engine is used in order to effec-
tively troubleshoot the problem. 410cc Engine, use Section 3.2
Problem 10 – Recoil Cord Will Not Pull
TEST 49 – TEST TEST 50 – VISUALLY INSPECT FOR OBSTRUCTIONS

RECOIL GOOD TEST ENGINE GOOD THAT WOULD CAUSE BINDING OF THE
FUNCTION FUNCTION RECOIL ONCE INSTALLED
BAD
BAD
VISUALLY INSPECT EXTERNAL

REPLACE COMPONENTS FOR A FAILURE
THAT WOULD CAUSE THE BAD FIX BAD COMPONENT
ENGINE TO BE SIEZED
NOTHING
AN INTERNAL ENGINE FAILURE HAS OCCURED.
FOUND
Problem 11 – Engine Starts Hard and Runs Rough
CHECK CHOKE TEST 26 – TEST 27 –

CHECK FUEL CHECK
GOOD POSITION AND GOOD CHECK GOOD GOOD
SUPPLY SPARK PLUG
OPERATION SPARK
LOW FUEL ENGINE MISS BAD

IS APPARENT
PUSH IN AFTER
STARTING REPLACE SPARK PLUG
REPLENISH
FUEL
SUPPLY REPLACE TEST 38 – CHECK
GOOD FLYWHEEL BAD REPLACE
MAGNETO
TEST 36 – CHECK
TEST 29 – TEST 40 – CHECK TEST 33 –
ENGINE / CYLINDER
CHECK GOOD AND ADJUST GOOD CHECK VALVE GOOD LEAK DOWN TEST /
CARBURETION GOVERNOR ADJUSTMENT
COMPRESSION TEST
BAD BAD BAD

GOOD
BAD
REPAIR ADJUST VALVES
REPAIR
OR REPLACE AND RETEST CHECK FLYWHEEL KEY
OR REPLACE
REPAIR OR REPLACE AS NECESSARY

REFER TO ENGINE SERVICE MANUAL
Page 34
Section 3.1
ENGINE TROUBLESHOOTING Part 3
Problem 12 – Engine Turns Over But Will Not Start
CHECK CHECK FUEL TEST 26 – TEST 39 – REMOVE

FUEL GOOD SHUTOFF GOOD CHECK BAD WIRE 18 /
SUPPLY VALVE SPARK SHUTDOWN LEAD
NO
SPARK
OFF
SPARK
REPLENISH
FUEL GOOD TEST 38 –
TURN
SUPPLY CHECK
ON
CHECK ENGINE FLYWHEEL
OIL LEVEL
BAD
TEST 27 –
CHECK SPARK OIL LEVEL LOW
GOOD REPLACE
PLUG
FLYWHEEL
OIL LEVEL O.K.
REPLENISH GOOD
OIL
BAD REPLACE
MAGNETO
TEST 29 –
CHECK BAD REPAIR
CARBURETION OR REPLACE
TEST 45 –
CHECK OIL TEST 24 – TEST
GOOD
LEVEL SWITCH OFF-ON SWITCH
BAD BAD
GOOD REPLACE SWITCH

REPLACE SWITCH
REPLACE LOW OIL ALARM GOOD
TEST 33 – TEST 36 – CHECK ENGINE /

CHECK VALVE GOOD CYLINDER LEAK DOWN TEST / GOOD
ADJUSTMENT COMPRESSION TEST
BAD BAD CHECK

FLYWHEEL
KEY
ADJUST AND REPAIR OR REPLACE AS NECESSARY
RE-TEST REFER TO ENGINE SERVICE MANUAL
Page 35
Section 3.1
Problem 13 – Engine “Hunts” / Erratic Idle

*Acceptable running limits for the engine are between 59-61 Hertz.
TEST 26 –
TEST 30 – TEST 33 –
STILL CHECK
CHOKE TEST CHECK VALVE GOOD
SURGING IGNTION
ADJUSTMENT
SPARK
NO BAD
SURGING GOOD BAD - ENGINE
MISS APPARENT
ADJUST / RE-TEST
TEST 29 – TEST 27 – CHECK

CHECK GOOD SPARK PLUG
CARBURETION
TEST 40 – CHECK
BAD
AND ADJUST
GOVERNOR
REPLACE
REPAIR OR
REPLACE BAD
TEST 38 –
REPLACE MAGNETO GOOD CHECK
FLYWHEEL
BAD
REPLACE
Page 36
Section 3.2
ENGINE TROUBLESHOOTING Part 3
410cc Troubleshooting flow charts
Problem 20 – Engine Will Not Crank
TEST 21 – CHECK TEST 22 – CHECK NO VOLTAGE TEST 23 – CHECK

BATTERY GOOD VOLTAGE AT MEASURED START-RUN-STOP
& CABLES STARTER SWITCH
CONTACTOR
BAD BAD
12 VDC
MEASURED
RECHARGE OR REPLACE BATTERY REPLACE
– CLEAN, REPAIR OR REPLACE
BAD CABLE(S)
TEST 25 – CHECK REPLACE STARTER
STARTER MOTOR BAD
MOTOR IF DEFECTIVE
GOOD
CHECK FOR MECHANICAL BINDING
OF THE ENGINE OR ROTOR
Problem 21 – Recoil Cord Will Not Pull (If So Equipped)
TEST 49 – TEST TEST 50 – VISUALLY INSPECT FOR OBSTRUCTIONS

RECOIL GOOD TEST ENGINE GOOD THAT WOULD CAUSE BINDING OF THE
FUNCTION FUNCTION RECOIL ONCE INSTALLED
BAD
BAD
VISUALLY INSPECT EXTERNAL

REPLACE COMPONENTS FOR A FAILURE
THAT WOULD CAUSE THE BAD FIX BAD COMPONENT
ENGINE TO BE SIEZED
AN INTERNAL ENGINE FAILURE HAS OCCURED.
POSSIBLE FAILURE COULD BE THE RESULT OF
NOTHING
A COMPRESSION RELEASE FAILURE. CONSULT
FOUND
ENGINE SERVICE MANUAL P/N 0C1103A FOR
FURTHER ENGINE SERVICE INFORMATION.
Page 37
Section 3.2
Part 3 DC control
Problem 22 – Engine Cranks But Will Not Start
CHECK CHECK FUEL TEST 26 –

PULL CHOKE
FUEL GOOD SHUTOFF GOOD FULL OUT CHECK
FULL OUT
SUPPLY VALVE SPARK
OFF
REPLENISH PULL OUT
FUEL
SUPPLY TURN BAD
ON
TEST 29 – TEST 27 –
CHECK GOOD CHECK SPARK GOOD
CARBURETION PLUG
BAD BAD
REPAIR
OR TEST 39 – REMOVE
REPLACE NO WIRE 18 /
REPLACE SPARK SHUTDOWN LEAD
GOOD
SPARK
TEST 38 –
FLYWHEEL
TEST 23 – TEST
BAD
START-RUN-STOP
BAD SWITCH
TEST 33 –
CHECK VALVE GOOD
REPLACE
ADJUSTMENT
REPLACE
GOOD
BAD
GO TO
TEST 36 – CHECK ENGINE /
“PROBLEM 24”
ADJUST AND CYLINDER LEAK DOWN TEST /
RE-TEST COMPRESSION TEST
GOOD
BAD
TEST 38 –
REPAIR OR REPLACE AS NECESSARY CHECK
REFER TO ENGINE SERVICE MANUAL FLYWHEEL KEY
P/N 0C1103A FOR FURTHER ENGINE
SERVICE INFORMATION
Page 38
Section 3.2
DC control Part 3
Problem 23 – Engine Starts Hard and Runs Rough

CHECK CHOKE TEST 26 – TEST 27 –
CHECK FUEL
GOOD POSITION AND GOOD CHECK GOOD CHECK GOOD
SUPPLY
OPERATION SPARK SPARK PLUG
LOW FUEL BAD

ENGINE MISS
PUSH IN AFTER IS APPARENT
STARTING REPLACE SPARK PLUG
REPLENISH
FUEL
SUPPLY
TEST 38 –
REPLACE MAGNETO GOOD CHECK BAD REPLACE
FLYWHEEL
TEST 29 – TEST 41 – CHECK TEST 33 –

CHECK GOOD AND ADJUST GOOD CHECK VALVE
CARBURETION GOVERNOR ADJUSTMENT
BAD
BAD BAD
GOOD
REPAIR
OR REPLACE REPAIR ADJUST VALVES
OR REPLACE AND RETEST
TEST 36 – CHECK CHECK FLYWHEEL KEY

GOOD
ENGINE / CYLINDER
LEAK DOWN TEST / REPAIR OR REPLACE AS NECESSARY
COMPRESSION TEST REFER TO ENGINE SERVICE MANUAL
BAD
P/N 0C1103A FOR FURTHER ENGINE
SERVICE INFORMATION
Problem 24 – Engine Starts Then Shuts Down

TEST 23 – TEST
CHECK ENGINE TEST 46 – TEST OIL
OIL LEVEL O.K. GOOD START-RUN-STOP
OIL LEVEL PRESSURE SWITCH
SWITCH
OIL LEVEL LOW BAD BAD GOOD
REPLACE SWITCH
REPLENISH REPLACE SWITCH
OIL
REPLACE OIL
PRESSURE MODULE
Page 39
Section 3.2
Problem 25 – Battery Will Not Charge
TEST 20 – REPLACE
CHECK CONNECTIONS
CHECK 1.5 GOOD GOOD BATTERY
ON BATTERY CHARGE
AMP FUSE CHARGER
SOCKET
BAD
BAD
REPLACE
REPLACE FUSE
Problem 26 – Engine “Hunts” / Erratic Idle

*Acceptable running limits for the engine are between 59-62 Hertz.
TEST 30 – STILL
CHOKE TEST SURGING
NO
SURGING TEST 33 – TEST 26 –
CHECK VALVE GOOD CHECK
ADJUSTMENT SPARK
TEST 29 –
CHECK BAD
GOOD
CARBURETION GOOD
ADJUST / RE-TEST
TEST 27 – CHECK BAD - ENGINE

GOOD SPARK PLUG MISS APPARENT
TEST 41 – CHECK
AND ADJUST BAD
GOVERNOR
REPAIR OR REPLACE
REPLACE BAD
TEST 38 –
FLYWHEEL
BAD
REPLACE
Page 40
NOTES
Page 41
Section 3.3
Part 3 DC control
Diagnostic tests
Test 20 – Check 1.5 Amp Fuse TEST 22 – Check Voltage at Starter

Contactor (SC)
PROCEDURE:
1. Set voltmeter to measure DC voltage.
2. Disconnect Wire 16 from the Starter Contactor located
on the Starter motor.
3. Connect the positive meter test lead to Wire 16 previ-
ously removed. Connect the negative meter test lead to
frame Ground.
4. Place the START-RUN-STOP Switch to START. 12 VDC
should be measured.
Figure 1. A Typical 1.5 Amp Fuse 5. Reconnect Wire 16 to the Starter Motor.
Discussion: RESULTS:
The fuse protects the wiring and the battery charger Refer back to flow chart.
from a short circuit.
PROCEDURE: TEST 23 – Check Start-Run-Stop Switch

Push in on fuse holder cap and turn counterclockwise.
Then, remove the cap with fuse. Inspect the fuse. Discussion:
RESULTS: The START-RUN-STOP switch utilizes ground potential
to start and shutdown the engine. When the switch is
If the fuse element has melted open, replace the fuse actuated to the START position a ground is applied to
with an identical size fuse. If fuse is good, refer back the starter contactor where positive 12VDC is already
to flow chart. available allowing the engine to crank. Once the ground
is removed by putting the switch in the RUN posi-
tion it disengages the starter allowing the engine to
Test 21 – Check Battery & Cables operate normally. When the switch is actuated to the
STOP position a ground is applied to the magneto coils
grounding them out and inhibiting spark from occurring.
PROCEDURE:
Inspect the battery cables and battery posts or termi-
nals for corrosion or tightness. Measure the voltage at STOP RUN START
the terminal of the Starter Contactor and verify 11-12
volts DC is available to the generator during cranking.
If voltage is below 11 volts DC, measure at the battery
terminals during cranking. If battery voltage is below
11 volts DC, recharge/replace battery. If battery or
cables are still suspected, connect an alternate bat-
1A 1 1B
tery and cables to the generator and retest.
RESULTS:
WHT 0 GD 13A
1. Clean battery posts and cables as necessary. Make sure
battery cables are tight. TO MAGNETO
2. Recharge the battery, if necessary. GROUND TO
3. Replace the battery, if necessary. STARTER CONTACTOR
4. If battery is good, but engine will not crank, refer back to

Flow Charts. Figure 2. START-RUN-STOP Switch
Procedure:
1. Set a voltmeter to measure resistance.
2. Remove all wires from the START-RUN-STOP Switch
(SW1).
Page 42
Section 3.3
DC control Part 3
Diagnostic tests
3. Connect one meter lead to Terminal 2 and connect the Procedure:

other meter lead to Terminal 1. Actuate switch to the 1. Disconnect Point A from the switch harness (see Figure 3).
START position. CONTINUITY should be measured.
2. Connect one meter lead to the female side of the con-
4. Actuate switch to the STOP position. INFINITY should be nector and connect other meter test lead to a clean
measured. frame ground.
5. Keep one meter lead on Terminal 2 and connect the 3. Actuate the switch back and forth between ON and
other meter lead to Terminal 3. Actuate switch to the OFF. CONTINUITY should only be measure in the OFF
STOP position. CONTINUITY should be measured. position.
6. Actuate switch to the START position. INFINITY should
be measured. RESULTS:
1. If switch failed Step 3, replace the OFF-ON switch.
7. Connect one meter test lead to disconnected Wire 0
from Terminal 2 and connect the other meter test lead to 2. If OFF-ON switch is good, refer back to flow chart.
the positive post of the battery, 12 VDC should be mea-
sured. If voltage is not measured, repair or replace Wire
Test 25 – Check Starter Motor
13A between the starter contactor and the START-RUN-
STOP switch. The following conditions can affect starter motor performance:
8. Reconnect all wires to the switch. 1. A binding or seizing condition in the Starter Motor bearings.
2. A shorted, open or grounded armature.
RESULTS:
a. Shorted, armature (wire insulation worn and
1. If anything but the readings above were measured wires touching one another). Will be indicated
replace the START-RUN-STOP switch. by low or no RPM.
b. Open armature (wire broken) will be indicated
2. Refer back to flow chart. by low or no RPM and excessive current draw.
c. Grounded armature (wire insulation worn and wire
touching armature lamination or shaft). Will be
Test 24 – Test OFF-ON Switch indicated by excessive current draw or no RPM.
Discussion:
3. A defective Starter Motor switch.
The OFF-ON switch applies a ground to the shutdown 4. Broken, damaged or weak magnets.
harness (Wire 18). By applying a ground to the har-
ness it grounds out the magneto and inhibits spark. 5. Starter drive dirty or binding.
00.01
TO FRAME GROUND
TO FRAME GROUND
OFF-ON SWITCH
OFF
ON
MAGNETO
OIL LEVEL ALARM
SHUTDOWN HARNESS
TEST POINT A WIRE 18
FROM OIL LEVEL SWITCH
Figure 3. OFF-ON Switch Test Points (389cc Engine)
Page 43
Section 3.3
Part 3 DC control
Diagnostic tests
PROCEDURE:
The battery should have been checked prior to this
test and should be fully charged.
Set a voltmeter to measure DC voltage (12 VDC).
Connect the meter positive (+) test lead to the Starter
Contactor stud which has the small jumper wire con-
nected to the Starter. Connect the common (-) test
lead to the Starter Motor frame.
Set the Start-Stop Switch to its START position and PINION
observe the meter. Meter should Indicate battery voltage,
Starter Motor should operate and engine should crank.
RESULTS:
1. If battery voltage is indicated on the meter but Starter Figure 5. Check Pinion Gear Operation
Motor did not operate, remove and bench test the
Starter Motor (see following test). TOOLS FOR STARTER PERFORMANCE TEST:
2. If battery voltage was indicated and the Starter Motor The following equipment may be used to complete a
tried to engage (pinion engaged), but engine did not performance test of the Starter Motor:
crank, check for mechanical binding of the engine or • A clamp-on ammeter.
rotor. • A tachometer capable of reading up to 10,000 rpm.
• A fully charged 12 volt battery.
NOTE: If a starting problem is encountered, the
engine itself should be thoroughly checked to Measuring Current:
eliminate it as the cause of starting difficulty. It is
a good practice to check the engine for freedom To read the current flow, in AMPERES, a clamp-on
of rotation by removing the spark plugs and turn- ammeter may be used. This type of meter indicates
ing the crankshaft over slowly by hand, to be sure current flow through a conductor by measuring the
it rotates freely. strength of the magnetic field around that conductor.
WARNING!: DO NOT ROTATE ENGINE WITH

* ELECTRIC STARTER WITH SPARK PLUGS
REMOVED. ARCING AT THE SPARK PLUG
ENDS MAY IGNITE THE GASOLINE VAPOR
EXITING THE SPARK PLUG HOLE.
STARTER
Figure 6. Clamp-On Ammeter
Tachometer:
Figure 4. Starter Motor (SM)
A tachometer is available from your Generac Power
Systems source of supply. Order as P/N 042223. The
CHECKING THE PINION: tachometer measures from 800 to 50,000 RPM (see
When the Starter Motor is activated, the pinion gear Figure 7).
should move and engage the flywheel ring gear. If the
pinion does not move normally, inspect the pinion for
binding or sticking.
Page 44
Section 3.3
DC control Part 3
Diagnostic tests
CLAMP ON
STARTER AMP METER
CONTACTOR
STARTER
MOTOR
Figure 7. Tachometer
METAL STOCK
1/4" THICK STEEL
2.625"
0.5"
0.5" 3.5"
TACHOMETER
1.0" 4" 12 VOLT
VISE BATTERY
12"
DRILL TWO HOLES — 1/2"

FOR STARTER
MOUNTING BRACKET
2" Figure 9. Testing Starter Motor Performance
Note: Take the reading after the ammeter and
DRILL TWO HOLES — 1/2"
FOR MOUNTING TACHOMETER tachometer are stabilized, approximately 2-4
TAP FOR 1/4-20 NC SCREWS
seconds.
4. A starter motor in good condition will be within the fol-
Figure 8. Test Bracket Dimensions lowing specifications:
Minimum rpm 4500
Test Bracket:
Maximum Amps 50
A starter motor test bracket may be made as shown in
Figure 8. Note: Nominal amp draw of starter in generator is
60 amps.
Remove Starter Motor:
It is recommended that the Starter Motor be removed
from the engine when testing Starter Motor perfor- Test 25 – Check Ignition Spark
mance. Assemble starter to test bracket and clamp
test bracket in vise (Figure 9). PROCEDURE:
A commercially available spark tester may be used
Testing Starter Motor: to test the engine ignition system. One can also be
1. A fully charged 12 volt battery is required. purchased from Generac Power Systems (Part No.
0C5969).
2. Connect jumper cables and clamp-on ammeter as
shown in Figure 9. 1. Disconnect the spark plug lead from a spark plug.
3. With the Starter Motor activated (jump the terminal on the 2. Attach the high tension lead to the spark tester terminal.
Starter Contactor to battery voltage), note the reading on 3. Ground the spark tester clamp by attaching to the cylin-
the clamp-on ammeter and on the tachometer (rpm). der head (see Figure 10).
Page 45
Section 3.3
Part 3 DC control
Diagnostic tests
SPARK TESTER
SPARK TESTER CLAMP
GROUNDED TO SPARK PLUG
CYLINDER HEAD BOOT
Figure 12. Setting Spark Plug Gap
NORMAL MISFIRES
Figure 10. Testing Ignition System
SPARK TESTER CLAMP

CONNECTED TO
SPARK PLUG SPARK TESTER
SPARK PLUG
BOOT
PRE-IGNITION DETONATION
Figure 11. Checking Engine Miss
4. Crank the engine rapidly. Engine must be cranking at Figure 13. Spark Plug Conditions
350 rpm or more. If spark jumps the tester gap, you may
assume the ignition system is working properly. Repeat RESULTS:
on remaining cylinder spark plug. 1. Clean and regap or replace sparks plug as necessary.
5. If spark jumps the tester gap intermittently, the problem 2. Refer back to the Flow Chart.
may be in the Ignition Magneto.
RESULTS: Test 29 – Check Carburetion

Refer back to the Flow Chart
PROCEDURE:
Before making a carburetion check, be sure the fuel sup-
Test 26 – Check Spark Plugs ply tank has an ample supply of fresh, clean gasoline.
Check that all shutoff valves are open and fuel flows
PROCEDURE: freely through the fuel line.
Remove spark plugs. Clean with a commercial solvent. Make sure the choke operates properly.
DO NOT BLAST CLEAN SPARK PLUGS. Replace
spark plugs if badly fouled, if ceramic is cracked, or If the engine will not start, remove and inspect the spark
if badly worn or damaged. Refer to specifications in plug. If the spark plug is wet, look for the following:
the front of this manual for proper replacement spark • Overchoking.
plugs and spark plug gaps. • Excessively rich fuel mixture.
Page 46
Section 3.3
DC control Part 3
Diagnostic tests
• Water in fuel. Test 33 – Check Valve Adjustment

• Intake valve stuck open.
• Needle/float stuck open. Adjusting Valve Clearance:
If the spark plug is dry look for the following: Improperly adjusted valves can cause various engine
• Leaking carburetor mounting gaskets. related problems including, but not limited to, hard starting,
• Intake valve stuck closed. rough running and lack of power.
• Inoperative fuel pump. Adjust valve clearance with the engine at room tem-
perature. The piston should be at top dead center
• Plugged fuel filter(s). (TDC) of its compression stroke (both valves closed).
• Varnished carburetor An alternative method is to turn the engine over and
If the engine starts hard or will not start, look for the position the intake valve fully open (intake valve spring
following: compressed) and adjust the exhaust valve clearance.
• Physical damage to the AC generator. Check the Turn the engine over and position the exhaust valve
Rotor for contact with the Stator. fully open (exhaust valve spring compressed) and
• Starting under load. Make sure all loads are discon- adjust the intake valve clearance.
nected or turned off before attempting to crank and Correct valve clearance is given below.
start the engine.
Engine Intake Valve Exhaust Valve
• Check that the choke is working properly.
189/206cc 0.0039 inch 0.0059 inch
1. Remove fuel line at carburetor and ensure that there is
an adequate amount of fuel entering the carburetor. 389cc 0.006 ±0.0008 inch 0.006 ±0.0008 inch
410cc 0.003-0.005 inch 0.003-0.005 inch
2. Remove the float bowl and check to see if there is any
foreign matter in bottom of carburetor bowl.
3. The float is plastic and can be removed for access to the
needle so it can be cleaned.
4. With all of this removed, carburetor cleaner can be used
to clean the rest of the carburetor before reassembly.
5. After cleaning the carburetor with an approved carbure-
tor cleaner, blow dry with compressed air and reas-
semble.
Shelf life on gasoline is 30 days. Proper procedures
need to be taken for carburetors so that the fuel doesn’t FEELER GAUGE
varnish over time. A fuel stabilizer must be used at all
times in order to ensure that the fuel is fresh at all times. ALLEN WRENCH
RESULTS:
If carburetor is varnished, clean or replace. Refer to
back to Flow Chart. Figure 14. Adjusting Valve Clearance
1. Loosen the rocker arm jam nut. Turn the pivot ball stud
Test 30 – Choke Test while checking the clearance between the rocker arm
and valve stem with a feeler gauge (see Figure 14).
Procedure: 2. When clearance is correct, hold the pivot ball stud with
If the generator is surging it may have a carburetion the allen wrench and tighten the rocker arm jam nut to
problem. A lean condition can cause erratic RPM.
Slowly pull the choke out to see if surging stops. If it the specified torque with a crow's foot. After tightening
does stop, carburetion should be checked. the jam nut, recheck valve clearance to make sure it did
not change.
Rocker Arm Jam Nut ft-lbs

189cc 7.48
206cc 7.48
389cc 9-12
410cc 14.01
Page 47
Section 3.3
Part 3 DC control
Diagnostic tests
4. Lock the flywheel at top dead center.

5. Attach cylinder leak down tester adapter to spark plug
hole.
CROW'S FOOT
6. Connect an air source of at least 90 psi to the leak down
tester.
7. Adjust the regulated pressure on the gauge to 80 psi.
8. Read the right hand gauge on the tester for cylinder
pressure. 20 percent leakage is normally acceptable.
Use good judgement, and listen for air escaping at the
carburetor, the exhaust, and the crankcase breather.
This will determine where the fault lies.
Results:
Figure 15. Tightening the Jam Nut • Air escapes at the carburetor – check intake valve.
• Air escapes through the exhaust – check exhaust valve.
Install Rocker Arm Cover • Air escapes through the breather – check piston rings.
• Air escapes from the cylinder head – the head gas-
1. Use a new rocker arm cover gasket. Install the rocker ket should be replaced.
arm cover and retain with four screws.
Check Compression:
Results: To check engine compression, remove the spark plug.
Adjust valves to specification and retest. If problem Insert an automotive type compression gauge into
continues, refer to Flow Chart. the spark plug hole. Crank the engine until there is
no further increase in pressure. The highest reading
obtained is the engine compression pressure.
Test 36 – Check Engine / Cylinder Leak
M I N I M U M A L L OWA B L E C O M P R E S S I O N
Down Test / Compression Test PRESSURE COLD ENGINE – 60 psi
If compression is poor, look for one or more of the fol-
Discussion: lowing causes:
Most engine problems may be classified as one or a • Loose cylinder head bolts.
combination of the following: • Failed cylinder head gasket.
• Will not start. • Burned valves or valve seats.
• Starts hard. • Insufficient valve clearance.
• Lack of power. • Warped cylinder head.
• Runs rough. • Warped valve stem.
• Vibration. • Worn or broken piston ring(s).
• Overheating. • Worn or damaged cylinder bore.
• High oil consumption. • Broken connecting rod.
• Worn valve seats or valves.
Discussion:
• Worn valve guides.
The Cylinder Leak Down Tester checks the sealing
(compression) ability of the engine by measuring air NOTE: Refer to Engine Service Manual Part
leakage from the combustion chamber. Compression Number 0C1103A for further engine service infor-
loss can present many different symptoms. This test mation on the 410cc engine.
is designed to detect the section of the engine where
the fault lies before disassembling the engine.
Test 38 – Check Flywheel
Procedure:
1. Remove the spark plug. Discussion:
2. Gain access to the flywheel. Remove the valve cover. In Test 25, a spark tester was used to check for
engine ignition. If sparking or weak spark occurred,
3. Rotate the engine crankshaft until the piston reaches top one possible cause might be the ignition magneto.
dead center (TDC). Both valves should be closed. This test will check the magnetism of the flywheel and
will check the flywheel key.
Page 48
Section 3.3
DC control Part 3
Diagnostic tests
2. Remove the flywheel cover so that the magneto is

ENGINE WIRE HARNESS exposed.
3. Disconnect Wire 18 from the magneto.
SPARK PLUG
WIRE 18 TO 4. Repeat Test 25, “Check Ignition Spark.”
START-RUN-STOP SWITCH
(SHUTDOWN LEAD)
RESULTS:
1. If spark now occurs, Wire 18 has a short to ground.
REMOVE LEAD
Trace Wire 18 back to the START-RUN-STOP switch
and Oil Pressure Module (If so equipped).
FLYWHEEL KEY 2. If spark still does not occur, refer back to flow chart.
WIRE 18
CONNECTION
Figure 16. Engine Ground Harness
PROCEDURE:
1. Check the flywheel magnet by holding a screwdriver at
the extreme end of its handle and with its point down.
When the tip of the screwdriver is moved to within 3/4 Figure 17. Wire 18 (410cc Engine)
inch (19mm) of the magnet, the blade should be pulled
in against the magnet.
2. For rough running or hard starting engines check the fly- OFF-ON SWITCH
wheel key. The flywheel’s taper is locked on the crankshaft
taper by the torque of the flywheel nut. A keyway is pro- OFF
vided for alignment only and theoretically carries no load ON
MAGNETO
Note: If the flywheel key becomes sheared or even
partially sheared, ignition timing can change.
Incorrect timing can result in hard starting or fail-
ure to start.
SHUTDOWN HARNESS
WIRE 18
TEST 39 – Remove Wire 18 / Shutdown
Lead Figure 18. Shutdown Lead (389cc Engine)
Discussion:
Test 40 – Check / Adjust Governor
Wire 18 on all engines is used to shutdown the unit
when either the switch is placed in the OFF posi- (389/206/163cc Engines)
tion or a low oil condition has occurred. A ground
is applied to the magneto in both instances which Initial Adjustment:
will inhibit spark and shutdown the unit. If a short to
ground exists on this wire the engine will be inhibited 1. Loosen the governor lever clamp bolt (See Figure
from producing spark. This test will check the integrity 19).
of the wire.
2. While holding the governor lever in its full “INC. RPM”
Note: The shutdown lead on units with the 389cc
engine will not be identified as Wire 18. Refer to position, rotate the governor shaft counter clockwise as
Figure 18 for identification of location. far as it will go.
Note: The governor shaft will only turn approx-
PROCEDURE: imately 20 degrees from a full clockwise posi-
1. Turn off the fuel supply tion. Do not apply excessive torque to the
governor shaft.
Page 49
Section 3.3
Part 3 DC control
Diagnostic tests
3. Tighten the governor lever clamp bolt to 110 inch- Test 41 – Check / Adjust Governor
pounds. (410cc Engine)
Running adjustment: DISCUSSION:
After completing the initial adjustment, final adjust- The generator AC frequency output is directly pro-
ment is accomplished with the engine running under portional to the speed of the rotor. A two-pole rotor
no-load. (having a single north and a single south magnetic
1. Turn the speed adjustment screw counter clockwise pole) will produce an AC frequency of 60 hertz at
three full turns to avoid a possible engine overspeed 3600 RPM.
condition. The generator is equipped with a “voltage over fre-
quency” type AC voltage regulator. The units AC out-
2. Start the engine and let it warm up and stabilize under put voltage is generally proportional to AC frequency.
no-load. A low or high governor speed will result in a corre-
spondingly low or high AC frequency and voltage out-
3. Connect an AC frequency meter to one of the AC output put. The governed speed must be adjusted before any
receptacles. No-load frequency should be between attempt to adjust the voltage regulator is made.
62.0 - 62.5 hertz.
PROCEDURE
4. If the frequency/RPM are incorrect, turn the speed adjust 1. Loosen the governor clamp bolt (Figure 20).
screw until frequency/RPM is within limits. Turn clock-
wise to increase frequency/RPM, counter clockwise to 2. Hold the governor lever at its wide open throttle position,
decrease the frequency/RPM (see Figure 19). and rotate the governor shaft clockwise as far as it will
go. Then, tighten the governor lever clamp bolt to 70
5. After adjustment is complete add a drop of removable inch-pounds (8 Nm).
loctite (Loctite 241) to the threads of the speed adjust
screw (see Figure 19). 3. Start the generator; let it stabilize and warm up at
no-load.
GOVERNOR
CLAMP BOLT
GOVERNOR SHAFT
APPLY
LOCTITE
GOVERNOR LEVER
HERE
SPEED ADJUST SCREW
INCREASE RPM
Figure 19. Governor Adjustment Points (389cc Engine)
Page 50
Section 3.3
DC control Part 3
Diagnostic tests
3. Set VOM to measure resistance.

GOVERNOR 4. Connect one meter test lead to the previously discon-
SHAFT nect wire coming from the oil level switch. Connect the
other meter test lead to frame ground. INFINITY should
be measured.
GOVERNOR
CLAMP Results:
BOLT
1. A reading of CONTINUITY indicates that the switch is no
PRIMARY
ADJUST longer functioning and will need to be replaced.
SCREW
Test 46 – Check Oil Pressure Switch

If the engine cranks and starts, then shuts down
almost immediately, the cause may be one or more of
the following:
• Low engine oil level.
Figure 20. Engine Governor Adjustment (410cc Engine) • Low oil pressure.
4. Connect a frequency meter across the generators AC • A defective oil pressure switch.
output leads.
5. Turn the primary adjust screw to obtain a frequency LOW OIL SWITCH
reading of 62.5 Hz.
6. When frequency is correct at no load, check the AC volt-
age reading. If voltage is incorrect, the voltage regulator
may require adjustment if so equipped.
RESULTS:
1. If, after adjusting the engine governor, frequency and
voltage are good, tests may be discontinued.
2. If frequency is now good, but voltage is high or low, refer
back to flow chart.
3. If engine was overspeeding, check linkage and throttle
for binding. If no governor response is indicated refer to
engine service manual. Figure 21. Low Oil Pressure Switch
4. If engine appears to run rough and results in low fre-
quency, proceed to Problem 26 Flow Chart. PROCEDURE:
1. Check engine crankcase oil level.
Test 45 – Check Oil Level Switch a. Check engine oil level.
b. If necessary, add the recommended oil to
Discussion: the dipstick FULL mark. DO NOT OVERFILL
ABOVE THE FULL MARK.
The 389cc engine does not utilize oil pressure to
lubricate the internal components. It utilizes a splash 2. Do the following:
type lubrication system. The switch should be nor- a. Disconnect Wire 86 and Wire 0 from the oil
mally open as long as the engine is filled with oil. The pressure switch terminals. Remove the switch
switch will close when the oil level drops to low the and install an oil pressure gauge in its place.
switch will close and ground out the magnetos inhibit-
ing spark until the oil level is raised. b. Start the engine while observing the oil pres-
sure reading on gauge.
Procedure: c. Note the oil pressure.
1. Verify that the oil level is full. (1) Normal oil pressure is approximately 35-40
psi with engine running. If normal oil pres-
2. Refer to Figure 3 in Section 3.3. Unplug the wire from sure is indicated, go to Step 4 of this test.
the oil level switch.
Page 51
Section 3.3
Part 3 DC control
Diagnostic tests
(2) If oil pressure is below about 10 psi, shut Test 49 – Test Recoil Function
engine down immediately. A problem exists
in the engine lubrication system. Refer to
Service Manual, Generac P/N 0F6923 for Procedure:
engine service recommendations. 1. Attempt to pull start the engine and make the following
Note: The oil pressure switch is rated at 10 psi for observations while doing so.
single cylinder engines. a. Does the cord pull easily and smoothly?
3. Remove the oil pressure gauge and reinstall the oil pres- b. Does the cord return with no assistance?
sure switch. Do NOT connect Wire 86 or Wire 0 to the c. Does the engine turn over as the cord is
switch terminals. pulled?
a. Set a voltmeter to measure resistance.
b. Connect the meter test leads across the switch Results:
terminals. With engine shut down, the meter If the recoil did not perform as the observations are
should read CONTINUITY. stated above, possible problems that could be present
are:
c. Crank and start the engine. The meter should
read INFINITY. • On the 410cc engine the compression release valve
could be broken.
d. Connect one test lead to Wire 0 ( disconnected from • The engine could be seized.
LOP). Connect the other test lead to a clean frame
ground. Continuity should be measured. If con- • The recoil could have become detached from the
tinuity is NOT measured repair or replace Wire 0 flywheel.
between the LOP and the ground terminal connec- • The recoil mechanism could be broken and not to
tion on the engine mount. properly retracting back into the engine.
4. If the LOP switch tests good in Step 3 and oil pressure is
good in Step 2, but the unit still shuts down with a LOP Test 50 – Test Engine Function
fault, check all wiring connections between the START-
STOP-RUN switch and the LOP pressure module and Procedure:
the LOP sender for a short to ground. Any ground on 1. Remove the recoil and front cover assembly.
this wire will cause Wire 18 to receive a ground also
inhibiting spark from occurring. If a short to ground is 2. Remove the spark plug from the unit.
found replace the respective wire. 3. Attempt to turn the engine over by hand.
RESULTS:
Results:
1. If LOP switch, oil pressure and wiring all test good, refer
1. If the engine can not turn over freely with the spark plug
back to flow chart.
removed, the engine has suffered some type of internal
2. If the LOP switch failed, replace the switch. failure that has seized it and is inhibiting it from running.
3. If no pressure was measured, an internal failure of the 2. Refer back to flow chart.
oil pump may have occurred.
Page 52
Table of contents
Part Title
4.1. Major Disassembly
PART 4
DISASSEMBLY
Page 53
Section 4.1
Part 4 Disassembly
Major Disassembly
Major Disassembly
Discussion.
Each generator will have its own unique method of disassembly. Provided is a simplified version of disassembly
that does not go into step by step instructions. The figure below represents the basic disassembly and sequence
of steps needed to remove the fuel tank, stator, rotor, and the engine. All of the GP series generators have these
major components and the order of disassembly would not change.
An exploded view of each GP Series generator model is provided on the following pages.
4
6
3
Figure 1. Basic Disassembly Steps
Page 54
Section 4.1
Disassembly Part 4
Major Disassembly
Page 55
Section 4.1
Part 4 Disassembly
Major Disassembly
Exploded View – GP1800 – Drawing No. 0H0609-A
Page 56
Section 4.1
Disassembly Part 4
Major Disassembly
ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION
1 1 ENGINE, 196CC
2 1 RECOIL ASSEMBLY
3 1 CARBURETOR
4 1 AIR CLEANER COVER
5 1 AIR FILTER
6 3 CARBURETOR GASKET
7 1 SPARK PLUG BOOT
8 1 OIL LEVEL SENSOR
9 1 FRAME, 1800W
10 1 FUEL SHUTOFF VALVE
11 2 VIBRATION MOUNT, #1
13 1 AVR
14 1 BRUSH ASSEMBLY
15 1 SPARK ARRESTOR
16 1 MUFFLER ASSEMBLY
17 1 FUEL TANK ASSEMBLY
18 1 FUEL TANK CAP ASSEMBLY
19 1 CONTROL PANEL ASSEMBLY
20 1 ASSEMBLY, ALTERNATOR 1800W
Page 57
Section 4.1
Part 4 Disassembly
Major Disassembly
Exploded View – GP3250 – Drawing No. 0H0522-C
PORTABLE KIT
Page 58
Section 4.1
Disassembly Part 4
Major Disassembly
1 1 ENGINE, 208CC 28 5 BOLT, FLANGE M6-1.0 X 40
2 1 RECOIL ASSEMBLY 29 2 BOLT, FLANGE M6-1.0 X 16
3 1 CARBURETOR 30 1 RUBBER GRIP, HANDLE 3250W
4 1 AIR CLEANER COVER 31 1 HANDLE, PORTABLE 3250W
5 1 AIR FILTER 32 1 ASSY, HANDLE BRACKET 3250W
6 3 CARBURETOR GASKET 33 1 ASSEMBLY, ALTERNATOR BRUSH

TYPE 3250W
7 1 SPARK PLUG BOOT
8 1 OIL LEVEL SENSOR
9 1 FRAME, 3250W
10 1 FUEL SHUTOFF VALVE
13 1 AVR
14 1 BRUSH ASSEMBLY
15 1 SPARK ARRESTOR
16 1 MUFFLER ASSEMBLY
17 1 FUEL TANK ASSEMBLY
18 1 FUEL TANK CAP ASSEMBLY
19 1 CONTROL PANEL ASSEMBLY
20 2 WHEEL, 7” DIAMETER 3250W
21 2 WHEEL AXLE M12-1.75 THREADS
22 2 NUT, AXLE M12-1.75
23 2 WASHER, FLAT M12
24 2 COTTER PIN
25 2 BUMPER BRACKET 3250W
26 7 NUT, FLANGE M6-1.0
27 2 RUBBER BUMPER, 3250W
Page 59
Section 4.1
Part 4 Disassembly
Major Disassembly
Exploded View – GP5000 – Drawing No. 0G9384A-C
26
28
33
27 38 39
31 34
32 29
9 40
30
14
8 41
35
36 37
42
16
15
12
43
11 10
46
1 13
45
44
5
47 2
55
25
54 24
7 23
17
4 19
6
3
20 18
51
53
52
50
48
49
Page 60
Section 4.1
Disassembly Part 4
Major Disassembly
1 1 FRAME PARTS 29 1 EXHAUST PARTS
2 1 ASSY CRADLE BASE 30 1 BRACKET, MUFFLER SHIELD, BOTTOM
3 1 CRADLE END 31 1 ASSY MUFFLER, 389cc
4 1 PANEL RAIL 32 1 BRACKET, MUFFLER SHIELD TOP
5 1 BACK RAIL 33 1 GASKET, EXHUAST. 389cc

CURVED HEAD BOLT 5/16-18 x 1.625"
6 10 34 8 SCREW HHTT M6-1.0 x 12
LONG
CAP NUT LOCKING 5/16-18, 5/16" OF
7 10 35 4 WASHER FLAT 5/16-M8 ZINC
THREAD
8 1 ENGINE/ALT PARTS 36 4 WASHER LOCK M8-5/16
9 1 ENGINE, 389cc W/O MUFFLER 37 4 SCREW HHC M8-1.25 x 12 G8.8 FT

VIB MOUNT RUBBER 1.38 x 1.0 x
10 4 38 2 STUD M8-125 x 35 G5 ZINC
5/16-18 MALE/FEMALE
11 4 WASHER LOCK M8-5/16 39 2 HEX NUT M8-1.25 G8 CLEAR ZINC
12 4 SCREW HHC 5/16-18 x 1-1/4 G5 40 4 SCREW HHC M6-1.0 x 16 C8.8
13 4 NUT LOCK FLG 5/16-18 41 1 SPACER .34 x .62 x .590 ST/ZNC

ALTERNATOR 6500W METRIC TAPER
14 1 42 1 SCREW HHC M8-1.25 x 30 C8.8
SHAFT
15 1 SCROLL, ALTERNATOR, SKU 43 1 ACCESSORY KIT
16 3 SCREW HHC M5-0.8 x 8 PC8.8 44 1 ASSY HANDLE LH

CARRIAGE HEAD BOLT 5/16-18 x 1.75"
17 1 ELECTRICAL PARTS 45 4
LONG
18 1 ASSY RCP PANEL 30A RD NOHR MTR 46 2
THREAD
19 1 ASSY POWER LEADS 47 1 ASSY HANDLE RH
TIRE 9.5" DIA RUN FLAT PLASTIC HUB/
20 4 SCREW PPPH #8-16 x 1/2" BZC 48 2
RUBBER TREAD
21 1 ASSY GND WIRE PNL TO ALT 49 2 SCREW HHFC 1/2-13 x 4.5 ZBC
22 1 ASSY GND WIRE ALT TO BASE 50 2 NUT LOCK HEX 1/2-13 NYL INS
23 1 WASHER LOCK SPECIAL 1/4" 51 1 FRAME, BENT, FOOT BLACK 03
24 1 LUG SLDLSS #2-#8 x 17/64 CU 52 2 RUBBER FOOT
25 1 SCREW HHTT M6-1.0 x 25 53 4 NUT LOCK FLG 5/16-18
26 1 FUEL TANK PARTS 6.6GL 54 2 WASHER FLAT 5/16-M8 ZINC
27 1 FUEL TANK ASSY 6.6 GAL 55 2 SCREW HHC 5/16-18 x 1/2 G5
28 4 SCREW HHTT M8-1.25 x 20
Page 61
Section 4.1
Part 4 Disassembly
Major Disassembly
Exploded View – GP5500 – Drawing No. 0H1253-A
Page 62
Section 4.1
Disassembly Part 4
Major Disassembly
2 1 ASSY CRADLE BASE 25 1 SCREW HHTT M6-1.0 X 25
3 1 CRADLE END 27 1 FUEL TANK ASSY 6.6 GAL PORTABLE
3A 1 ASSEMBLY, FRAME 1 PIECE 28 4 SCREW HHTT M8-1.25 X 20
4 1 PANEL RAIL 29 1 FUEL CAP, VENTED
5 1 BACK RAIL 30 1 SHIELD, HEAT, SKU
6 10 CURVED HEAD BOLT M8-1.25 X 42MM 31 1 BRACKET, MUFFLER 389CC
7 11 CAP NUT LOCKING M8-1.25 32 1 MUFFLER, 389CC
9 1 ENGINE, 389cc W /0 MUFFLER 33 1 GASKET, EXHAUST 389CC

VIB MOUNT RUBBER 35MM X 25.4 X
10 4 34 4 SCREW HHTT M6-1.0 X 12
M8-1.25
11 4 WASHER LOCK M8-5/16 35 4 WASHER FLAT 5/16-M8 ZINC
12 4 SCREW HHC M8-1.25 X 30 36 4 WASHER LOCK M8-5/16
13 8 NUT LOCK FLG M8-1.25 37 4 SCREW HHC MB-1.25 X 20 G8.8 FT
14 2 WASHER FLAT 13mm 38 2 STUD M8-1.25 X 35 G5 ZINC
15 1 ALTERNATOR 39 2 HEX NUT M8-1.25 G8 CLEAR ZINC
15A * AVR 44 1 ASSY HANDLE LH

CARRIAGE HEAD BOLT M8-1.25 X
15B * BRUSH-ALTERNATOR 45 4
46mm LONG
15C 1 SCROLL, ALTERNATOR, SKU 47 1 ASSY HANDLE RH
TIRE 9,5" DIA RUN FLAT PLASTIC HUB/
16 3 SCREW HHC M5-0.8 X 8 PC8.8 48 2
RUBBER TREAD
17 1 CLAMP HOSE .38-.87 49 2 AXLE PIN, 1/2" X 4", 3/4" HEAD
18 1 FUEL HOSE, 4 ID, 8.5 OD X 120MM 50 2 COTTER PIN, 1/8" X 1 1/4" ZN PLT
20 4 SCREW PPPH #8-16 X 1/2" BZC 51 1 FRAME, BENT, FOOT
21 1 ASSY RCP PANEL 25A RD W/HR MTR 52 2 RUBBER FOOT, M8-1.25
22 1 ASSY GND WIRE ALT TO BASE 54 2 WASHER FLAT 5/16-M8 ZINC
23 1 WASHER LOCK SPECIAL 1/4" 55 2 SCREW HHC M8-1.25 X 15
24 1 LUG SLDLSS #2-#8 X 17/64 CU
Page 63
Section 4.1
Part 4 Disassembly
Major Disassembly
Exploded View – GP6500 – Drawing No. 0G9384B-C
26
28
33 39 34
27 38
31
29
32
40
9
30
14
8
35
16 36 37
15 12
41
11 10
13
44
1
43
42
45 5
2
53
25
7 52 24
17 23
4
19
6
3
20
18
49
51
50 48
47
46
Page 64
Section 4.1
Disassembly Part 4
Major Disassembly
1 1 FRAME PARTS 28 4 SCREW HHTT M8-1.25 x 20
2 1 ASSY CRADLE BASE 29 1 EXHAUST PARTS
3 1 CRADLE END 30 1 BRACKET, MUFFLER SHIELD, BOTTOM
4 1 PANEL RAIL 31 1 ASSY MUFFLER, 389cc
5 1 BACK RAIL 32 1 BRACKET, MUFFLER SHIELD TOP

6 10 33 1 GASKET, EXHUAST. 389cc
LONG
7 10 34 8 SCREW HHTT M6-1.0 x 12
THREAD
8 1 ENGINE/ALT PARTS 35 4 WASHER FLAT 5/16-M8 ZINC
9 1 ENGINE, 389cc W/O MUFFLER 36 4 WASHER LOCK M8-5/16

10 4 37 4 SCREW HHC M8-1.25 x 12 G8.8 FT
5/16-18 MALE/FEMALE
11 4 WASHER LOCK M8-5/16 38 2 STUD M8-125 x 35 G5 ZINC
12 4 SCREW HHC 5/16-18 x 1-1/4 G5 39 2 HEX NUT M8-1.25 G8 CLEAR ZINC
13 4 NUT LOCK FLG 5/16-18 40 4 SCREW HHC M6-1.0 x 16 C8.8

ALTERNATOR 6500W METRIC TAPER
14 1 41 1 ACCESSORY KIT
SHAFT
15 1 SCROLL, ALTERNATOR, SKU 42 1 ASSY HANDLE LH
CARRIAGE HEAD BOLT 5/16-18 x 1.75"
16 3 SCREW HHC M5-0.8 x 8 PC8.8 43 4
LONG
17 1 ELECTRICAL PARTS 44 2
THREAD
18 1 ASSY RCP PANEL 30A RD NOHR MTR 45 1 ASSY HANDLE RH
TIRE 9.5" DIA RUN FLAT PLASTIC HUB/
19 1 ASSY POWER LEADS 46 2
RUBBER TREAD
20 4 SCREW PPPH #8-16 x 1/2" BZC 47 2 SCREW HHFC 1/2-13 x 4.5 ZBC
21 1 ASSY GND WIRE PNL TO ALT 48 2 NUT LOCK HEX 1/2-13 NYL INS
22 1 ASSY GND WIRE ALT TO BASE 49 1 FRAME, BENT, FOOT BLACK 03
23 1 WASHER LOCK SPECIAL 1/4" 50 2 RUBBER FOOT
24 1 LUG SLDLSS #2-#8 x 17/64 CU 51 4 NUT LOCK FLG 5/16-18
25 1 SCREW HHTT M6-1.0 x 25 52 2 WASHER FLAT 5/16-M8 ZINC
26 1 FUEL TANK PARTS 6.6GL 53 2 SCREW HHC 5/16-18 x 1/2 G5
27 1 FUEL TANK ASSY 6.6 GAL
Page 65
Section 4.1
Part 4 Disassembly
Major Disassembly
Exploded View – GP7000 – Drawing No. 0G9384D-B
Page 66
Section 4.1
Disassembly Part 4
Major Disassembly
1 1 CRADLE END 30 1 LUG SLDLSS #2-#8 X 17/64 CU
2 1 BACK RAIL 31 1 WASHER LOCK SPECIAL 1/4"
CURVED HEAD BOLT 5/16-18 x 1.625" 32 4 SCREW PPPH #8-16 x 1/2" BZC
3 10
LONG
CAP NUT LOCKING 5/16-18 THREAD, 33 1 ASSY GND WIRE ALT TO BASE
4 10
5/16" OF THREAD
RECEPTACLE PANEL 30A RND W/HR
34 1
5 1 PANEL RAIL MTR
6 1 ASSY CRADLE BASE 35 1 SCREW HHTT M6-1.0 x 25 BP
10 3 WASHER LOCK M8-5/16 55 1 ACCESSORY KIT
11 3 SCREW HHC 3/8-16 x 1-1/4 G5 56 1 ASSY HANDLE LH
12 1 SCREW HHC 5/16-24 x 1-1/4 G5 57 4 CHB CUSTOM 5/16 18 x 46MM LONG

13 2 SCREW HHC 5/16-18 x 1-1/4 G5 58 2
THREAD
14 3 WASHER LOCK M10 59 1 ASSY HANDLE RH
15 8 NUT LOCK FLG 5/16-18 TIRE 9.5" DIA RUN FLAT PLASTIC
60 2
HUB/RUBBER TREAD
16 1 ALTERNATOR, 7000W 61 2 SCREW, HHC 1/2"-13 x 4-1/2" LONG
VIB MOUNT RUBBER 1.38 x 1.0 x NUT, LOCK HEX 1/2-13 NYLON
17 2 62 2
5/16-18 MALE/FEMALE INSERT
18 1 ENGINE, GH410 63 1 FRAME, BENT, FOOT
19 1 BRACKET, MOUNT 64 2 RUBBER FOOT

20 2 65 4 NUT LOCK FLG 5/16-18
5/16-18 M/M
21 2 WASHER LOCK M6-1/4 66 2 WASHER FLAT 5/16-M8 ZINC
22 2 WASHER FLAT 5/16-M8 ZINC 67 2 SCREW HHC 5/16-18 X 1/2 G5
23 2 WASHER FLAT 1/4-M6 ZINC 68 1 FRAME, BENT, FOOT SUPPORT
24 2 SCREW HHC 5/16-18 x 1-1/2 G5 69 2 WASHER FLAT 1/2 ZINC
25 2 SCREW HHC M6-1.0 x 16 C8,8 70 4 SCREW HHTT M8-1.25 X 20
26 1 BRACKET, MOUNTING, MUFFLER 410 71 1 FUEL TANK ASSY 8.0 GAL PORTABLE
CLAMP HOSE .38-.87 [NOT SHOWN, 72 1 FUEL CAP-VENTED

27 1
FUEL HOSE]
28 1 CAPACITOR, VOLTAGE REG VS
Page 67
Section 4.1
Part 4 Disassembly
Major Disassembly
Exploded View – GP8000 – Drawing No. 0G9384F-B
Page 68
Section 4.1
Disassembly Part 4
Major Disassembly
1 1 CRADLE END TIRE 9.5" DIA RUN FLAT PLASTIC

60 2
HUB/RUBBER TREAD
2 1 BACK RAIL
61 2 SCREW, HHC 1/2"-13 x 4-1/2" LONG
3 10 NUT, HEX LOCK 1-2"-13 NYLON
LONG 62 2
INSERT
CAP NUT LOCKING 5/16-18 THREAD)
4 10 63 1 FRAME, BENT, FOOT
5/16" OF THREAD
5 1 PANEL RAIL 64 2 RUBBER FOOT
6 1 ASSY CRADLE BASE 65 4 NUT LOCK FLG 5/16-18
10 2 WASHER FLAT 5/16-M8 ZINC 66 2 WASHER FLAT 5/16-M8 ZINC
11 2 NUT HEX LOCK M8-1.25 NY INS 67 2 SCREW HHC 5/16-18 x 1/2 G5

VIBE MOUNT 25.0 x 31.8 x M8-1.25 68 1 FRAME) BENT, FOOT SUPPORT
12 2
M/M
69 2 WASHER FLAT 1/2 ZINC
13 4 NUT LOCK FLG 5/16-18
70 4 SCREW HHTT M8-1.25 x 20
14 1 ASSEMBLY ENGINE GH-410
71 1 FUEL TANK ASSY 8.0 GAL
15 1 ALTERNATOR 8000W
72 1 FUEL CAP-VENTED
16 2
5/16-18 MALE/MALE 75 1 BEARING CARRIER REAR
17 2 WASHER LOCK M6-1/4 76 1 STATOR 8KW
18 2 WASHER FLAT 1/4-M6 ZINC (CASTING) ENGINE ADAPTER
77 1
HOUSING
19 2 SCREW HHC M6-1.0 x 16 C8.8
78 I ROTOR ASSEMBLY, 8kW
20 1 SCREW HHTR 5/16-18 x 3/4
79 I CAPACITOR
21 1 BRACKET MUFFLER
80 I CLAMP
22 4 SCREW FHSC 3/8-16 x 3/4
81 5 WASHER LOCK M8-5/16
CLAMP HOSE .38-.87 [NOT SHOWN,
23 1
FUEL HOSE] 82 4 SCREW IHHC M8-1.25 x 140 G8.8
30 1 LUG SLDLSS #2-#8 x 17/64 CU 83 1 WASHER FLAT 5/16-M8 ZINC
31 1 WASHER LOCK SPECIAL 1/4" 84 1 SCREW IHHC 5/16-24 x 8-1/2 G5
32 4 SCREW PPPH #8-16 x 1/2" BZC 85 1 COVER ALTERNATOR INLET
33 1 ASSY GND WIRE ALT TO BASE 86 1 GROMMET WIRE SLEEVE
34 1 ASSY RCP PNL 8KW 30A W/HR MTR 87 2 SCREW PPHM M4-0,7 x 10
35 1 SCREW HHTT M6-1.0 x 25 BP 88 4 WASHER FLAT #10 ZINC
55 1 ACCESSORY KIT 89 4 WASHER LOCK #10
56 1 ASSY HANDLE LH 90 4 SCREW PPHM M5-0,8 x 30
57 4 CHB CUSTOM 5/16 18 x 46MM LONG 91 1 SCREW HHTT M6-1.0 x 12
CAP NUT LOCKING 5/16-18, 5/16" OF ALTERNATOR FAN VARIED BLADE
58 2 92 1
THREAD SPACING
59 1 ASSY HANDLE RH
Page 69
Section 4.1
Part 4 Disassembly
Major Disassembly
Page 70
Table of contents
DWG# Title Page
0H0612-A Electrical Schematic, GP1850 72
PART 5 0H0523-A
0G9769-C
Electrical Schematic, GP3250
Electrical Schematic,
73
74
ELECTRICAL 0G9769-C
GP5000/5500/6500
Wiring Diagram, 75
DATA 0G9849-A
GP5000/5500/6500
Electrical Schematic, 76
GP7000E/8000E
0G9849-A Wiring Diagram, 77
GP7000E/8000E
Electrical Formulas 78
Page 71
Electrical Schematic, GP1850 Part 5 Electrical Data
Brushed Alternator Drawing No. 0H0612-A
SENSING
DPE
Page 72
Electrical Data Part 5 Electrical Schematic, GP3250
Brushed Alternator Drawing No. 0H0523-A
SENSING
DPE
Page 73
Electrical Schematic, GP5000/5500/6500 Part 5 Electrical Data
Brushed Alternator Drawing No. 0G9769-C
Page 74
Electrical Data Part 5 Wiring Diagram, GP5000/5500/6500
Brushed Alternator Drawing No. 0G9769-C
Page 75
Electrical Schematic, GP7000E/8000E Part 5 Electrical Data
Brushless Alternator Drawing No. 0G9849-A

Page 76
Electrical Data Part 5 Wiring Diagram, GP7000E/8000E
Brushless Alternator Drawing No. 0G9849-A

Page 77
Electrical formulas
TO FIND KNOWN VALUES 1-PHASE
ExI
KILOWATTS (kW) Volts, Current, Power Factor
1000
ExI
KVA Volts, Current
1000
kW x 1000
AMPERES kW, Volts, Power Factor
E
WATTS Volts, Amps, Power Factor Volts x Amps
2 x 60 x Frequency
NO. OF ROTOR POLES Frequency, RPM
RPM
RPM x Poles
FREQUENCY RPM, No. of Rotor Poles
2 x 60
2 x 60 x Frequency
RPM Frequency, No. of Rotor Poles
Rotor Poles
HP x 0.746
kW (required for Motor) Motor Horsepower, Efficiency
Efficiency
E
RESISTANCE Volts, Amperes
I
VOLTS Ohm, Amperes IxR
E
AMPERES Ohms, Volts
R
E = VOLTS I = AMPERES R = RESISTANCE (OHMS) PF = POWER FACTOR
Page 78
NOTES
NOTES
Page 80
Generac Power Systems, Inc.
Part No. 0H0285 rev. A / Printed in USA 02.09
S45 W29290 Hwy. 59 • Waukesha, WI 53189
© 2009 Generac Power Systems, Inc. All rights reserved. 1-888-GENERAC (1-888-436-3722) • generac.com

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GP Series Portable Generators

NOTICE TO USERS OF THIS MANUAL

Product Series GP1800

A (2) 5-20R 120V Fuel Tank Capacity (Gal) 4

Product Series GP3250

Product Series GP5000

Product Series GP5500

Extended Length (EL) 47 Hour Meter with

Product Series GP6500

H Hour Meter with Maintenance Reset Height (H) 27.5

Product Series GP7000

Spark Plug Gap 0.030" (0.76mm) N (2) 30A

Oil Capacity 1.5 quart w/filter

Product Series GP8000/GP8000E

A Fuel Shut Off Manual Lever

1.1 Generator Fundamentals 10

INFORMATION 1.5 Testing, Cleaning and Drying 20

GP Series Portable Generators

Part 1 – General Information................................... 9 Section 1.3 – Brushless, Capacitor

Magnetism NOTE: The “right hand rule” is based on the “cur-

A Simple AC Generator A More Sophisticated AC Generator

The ROTOR may be a 2-pole type having a single 120 VAC

Figure 6. Capacitive Discharge

Figure 5. Alternating Current Sine Wave

240 VAC 240 VAC

STATOR STATOR STATOR STATOR

STATOR STATOR AUTOMATIC

A CAPACITIVE DISCHARGE B DIRECT EXCITATION

Figure 8. Generator Operating Diagram

The revolving magnetic field is driven by the engine 2. See Figure 8.

Meters Measuring AC Voltage

Figure 4. A VOM as an In-line meter

Component testing may require a specific resis- OHM:

VOLTS = AMPERES x OHMS

Introduction a tapered crankshaft and is held in place with a single

rotor is rectified using a diode. The magnetic lines of

Figure 2. Rotor and Diodes

Figure 1. AC Generator Exploded View

Rotor Assembly STATOR

Operation FIELD EXCITATION:

AC POWER WINDING OUTPUT:

BLUE (R1 – 44)

ENGINE Voltage Regulator

Stator Assembly ON-SPEED OPERATION:

windings and through the negative (-) slip ring and

TheMLB greater the current

CAPACITOR Figure 2. 240 VAC Sensing Alternator

A CAPACITIVE DISCHARGE B DIRECT EXCITATION

RED (R2 – 11)

BLUE (R1 – 22)

2.1 Brushless Excitation 22

GP Series Portable Generators

Part 2 – AC Generators.......................................... 21 Test 4 – Field Flash Alternator

If Problem Involves AC Output

GO TO PROBLEM 2 GO TO PROBLEM 4 GO TO PROBLEM 1 VERIFY ROTOR IS SPINNING, GO TO PROBLEM 3

Problem 1 – Generator Produces Zero Voltage or Residual Voltage

TEST 8 – TEST TEST 6 –

Problem 2 – Voltage & Frequency Are Both High or Low

FREQUENCY GOOD, LOW OR GO TO

Problem 3 – Excessive Voltage/Frequency Droop When Load is Applied

TEST 10 – CHECK TEST 11 – CHECK

GOOD OVERLOADED REDUCE LOAD

Warning: The capacitor may need to be dis-

Warning: Use proper protective equipment